W GWC Manual

Model
GWC
Gas-Fired Water Boilers
Boiler Manual
• Installation • Maintenance
• Startup • Parts
This manual must only be used by a qualified

heating installer/service technician. BEFORE
installing, read all instructions in this manual
and all other information shipped with the boiler.
Perform steps in the order given. Failure to
comply could result in severe personal injury,
death or substantial property damage.
Part number 550-142-056/0411

GWC gas-fired water boiler — Boiler Manual
How it works . . .
1 Integrated boiler control
The integrated boiler control (IBC) responds to signals from the room thermostat, air
pressure switch, inlet water sensor and boiler limit circuit to operate the circulators, LEGEND
gas valve, igniter and blower. When a room thermostat calls for heat, the IBC starts the
system circulator and blower. a Supply to system, 1” NPT
The IBC runs the blower to purge the boiler flue passages, then turns on the igniter and
lets it warm up.
b Return from system, 1” NPT
After igniter warm-up, the IBC opens the gas valve, turns the igniter off, and checks for
flame. The flame must come on within 4 seconds or the IBC will shut down and try the
full cycle again. c Combustion air inlet fitting —
When the room thermostat is satisfied, the IBC turns off the boiler components and 3” PVC connection
waits for the next heat call.
The IBC indicator lights show normal sequence when the lights are on steady. When a
problem occurs, the IBC flashes combinations of lights which indicate the most likely d Flue outlet — 3” PVC connec-
reason for the problem. tion
2 Transformer
e Gas valve — negative pressure
The control transformer reduces line voltage to 24 volts for the gas valve and limit
circuit. regulated gas control
3 Blower f Pressure/temperature gauge

The blower pulls in air and mixes it with gas from the gas valve. The blower forces this
mixture into the burner for combustion inside the boiler chamber.
g Flueway inspection port cover
4 Recuperator
The recuperator is a stainless steel heat exchanger that increases boiler efficiency by ex- h Sensor hose trap
tracting additional heat from the flue gases. Return water passes through the recuperator
before entering the boiler.
i Manual air vent
5 Water temperature limit switch
The water temperature limit switch turns off the gas valve if the temperature in the j Relief valve
boiler goes above its setting. (The circulators will continue to run as long as there is a
call for heat.)
k Thermal fuse — a one-time fuse
6 System circulator device that shuts boiler off if flue
The system circulator circulates water through the external (system) piping. The flow temperature exceeds its setpoint
rate of the circulator is controlled by the IBC, depending on the temperature of the water
entering the boiler sections. Pump must remain on boiler — do not remove.
m Condensate trap line — shipped
7 Bypass circulator loose with boiler, field installed
The IBC operates the bypass circulator to mix hot water from the boiler outlet with
colder return water from the system as needed to prevent condensation of flue gases in
the cast iron heat exchanger. n Condensate drain connection —
When the water returning to the boiler is below 140°F, the IBC regulates the bypass cir-
½” PVC female
culator and system circulator flow rates to raise the return water temperature up to 140°F
before it enters the cast iron sections. By balancing these flow rates, the IBC can protect
against condensation in the cast iron heat exchanger even if return water is as low as 60°F.
Pump must remain on boiler — do not remove.
8 Air pressure switch

The air pressure switch signals the IBC, telling the control whether air is moving through This boiler uses a negative-pressure-
the blower.
regulated gas valve, set for an outlet
9 Water temperature sensor pressure approximately –0.20” water
The water temperature sensor monitors the temperature of the water entering the boiler column.
sections. The sensor sends this information to the IBC. The IBC determines how much
to adjust the circulator flow rates to provide at least 140°F water to the cast iron heat DO NOT set the outlet pressure higher
exchanger. than factory setting.
2 Part number 550-142-056/0411

GWC Water Boiler
Part number 550-142-056/0411 3

Contents
How it works . . . . . . . . . . . . . 2 DIRECT VENT — Boiler room air Gas valve adjustment — altitude
openings . . . . . . . . . . . . . . 36 over 5,500 feet ONLY . . . . . . . . . . . . 60
GWC Water Boiler . . . . . . . . . 3 Final checklist . . . . . . . . . . . . . . . . 62
DIRECT VENT — Sidewall with sepa-
Please read before proceeding . . 5 rate pipes . . . . . . . . . . . . . 37 Annual start-up and general mainte-
nance schedule . . . . . . . . . . 65
Prepare boiler location . . . . . . . 6 DIRECT VENT — Sidewall with 3”
Installations must follow these codes: . . . 6 concentric . . . . . . . . . . . . . 39 Annual start-up . . . . . . . . . . 66
High altitude installations . . . . . . . . . 6 Address reported problems . . . . . . . . 66
Residential garage installation . . . . . . . 7 DIRECT VENT — Vertical with sepa- Inspect boiler area . . . . . . . . . . . . . 66
Check orifice plate — replace if necessary 8 rate pipes . . . . . . . . . . . . . 41 Inspect boiler interior . . . . . . . . . . . 66
Install condensate trap . . . . . . . . . . . 9 Inspect condensate drain system . . . . . 66
Install high altitude air pressure switch when DIRECT VENT — Vertical with 3” Inspect all piping for leaks . . . . . . . . . 66
required (only above 5,500 feet) . . . . . . 10 concentric . . . . . . . . . . . . . 43 Inspect gas piping . . . . . . . . . . . . . 66
Rotate the boiler into position . . . . . . . 10 Inspect the water system . . . . . . . . . . 66
Perform hydrostatic pressure test . . . . . 11 Concentric termination assembly Check water system chemistry . . . . . . . 66
(sidewall or vertical) . . . . . . . 45 Inspect expansion tank . . . . . . . . . . . 67
Install water piping . . . . . . . . 12 Inspect air openings . . . . . . . . . . . . 67
General piping information . . . . . . . . 12 Vent and air piping and boiler con- Inspect vent system and air piping . . . . 67
Install relief valve . . . . . . . . . . . . . . 12 nections . . . . . . . . . . . . . . 46 Inspect boiler heating surfaces . . . . . . . 67
Expansion tank . . . . . . . . . . . . . . . 13 DIRECT EXHAUST & DIRECT VENT . . 46 Inspect igniter . . . . . . . . . . . . . . . . 67
System water piping methods . . . . . . . 15 Follow termination instructions . . . . . . 46 Inspect recuperator . . . . . . . . . . . . . 68
Circulators . . . . . . . . . . . . . . . . . 15 Installing vent and air piping . . . . . . . 46 Inspect temperature mixing system . . . . 68
Simplified pipe/circulator selection . . . . 15 DIRECT EXHAUST ONLY . . . . . . . . 46 Inspect limit controls and cutoffs . . . . . 68
Baseboard system piping — Inspect gauges . . . . . . . . . . . . . . . 68
CIRCULATOR zoning (primary/secondary) DIRECT EXHAUST — Boiler room air Inspect blower motor . . . . . . . . . . . 68
16 openings . . . . . . . . . . . . . . 47 Inspect oiled-bearing circulators . . . . . 68
Baseboard system piping — Combustion air provision . . . . . . . . . 47 Inspect boiler relief valve . . . . . . . . . . 69
ZONE VALVE zoning (direct connection) 16 Sizing combustion air openings . . . . . . 47 To complete Annual Start-up, perform
Radiator system piping . . . . . . . . . . . 18 Special considerations . . . . . . . . . . . 47 startup and checks: . . . . . . . . . . . . . 69
Single-zone radiant heating or heat pump 19 GWC boiler Review with owner . . . . . . . . . . . . . 69
Adjust balancing valves . . . . . . . . . . . 19 WITHOUT other
Multi-zone radiant heating system . . . . 20 appliances in room . . . . . . . . . . . . . 48 Service & maintenance . . . . . . 70
Piping snow melt systems or combination Air openings . . . . . . . . . . . . . . . . 48 Cleaning boiler heating surfaces . . . . . . 70
snow melt/space heating systems . . . . . 21 GWC boiler Inspecting and cleaning the recuperator . 71
Water chiller systems . . . . . . . . . . . . 22 WITH other
appliances in room . . . . . . . . . . . . . 48 Troubleshooting . . . . . . . . . . 73
Multiple boiler installations . . . 23 VERIFY PROPER OPERATION AFTER
Placing multiple boilers . . . . . . . . . . 23 DIRECT EXHAUST — Sidewall . . 49 SERVICING. . . . . . . . . . . . . . . . . 73
Controlling multiple GWC boilers . . . . 23 Before troubleshooting . . . . . . . . . . . 73
DIRECT EXHAUST — Vertical . . 51 Check the following . . . . . . . . . . . . 73
Piping multiple GWC boilers . . . . . . . 23
Checking the air pressure switch . . . . . 73
Multiple boiler water piping . . . 24 Gas piping . . . . . . . . . . . . . 52 Igniter . . . . . . . . . . . . . . . . . . . . 74
Connecting gas supply piping . . . . . . . 52 Gas Valve . . . . . . . . . . . . . . . . . . 74
Secondary header piping installation . . . 24
Natural Gas . . . . . . . . . . . . . . . . . 53 Blower Housing . . . . . . . . . . . . . . . 74
Venting & air — general . . . . . 29 Propane Gas . . . . . . . . . . . . . . . . . 53 Thermal fuse . . . . . . . . . . . . . . . . 74
When removing a boiler from an existing Return temperature sensor . . . . . . . . 74
common vent system . . . . . . . . . . . . 29 Wiring . . . . . . . . . . . . . . . 54
IBC (integrated boiler control) . . . . . . 75
Existing vent test procedure . . . . . . . . 29 IBC indicator lights — lockout modes . . 75
Start-up . . . . . . . . . . . . . . 57
Provide combustion air: . . . . . . . . . . 30 IBC indicator lights —
Vent and air termination options . . . . . 30 Freeze protection (when used) . . . . . . 57 non-lockout modes . . . . . . . . . . . . . 75
DIRECT VENT installations . . . . . . . . 30 Clean system to remove sediment . . . . . 57
Water chemistry . . . . . . . . . . . . . . 57 Replacement parts . . . . . . . . 87
DIRECT EXHAUST installations . . . . . 30
Antifreeze . . . . . . . . . . . . . . . . . . 57
Combustion air contamination: . . . . . . 30
Check for gas leaks . . . . . . . . . . . . . 58 Dimensions and ratings . . . . . 98
Manifolded combustion air option for
DIRECT VENT multiple boiler installations Fill and test water system . . . . . . . . . . 58
31 Verify gas/air orifice plate . . . . . . . . . 59 NOTES . . . . . . . . . . . . . . 102
Air manifold sizing . . . . . . . . . . . . . 31 Check thermostat circuit(s) . . . . . . . . 59
Inspect/fill condensate system . . . . . . . 59 Handling ceramic fiber and
Commonwealth of Massachusetts Final checks before starting boiler . . . . . 60 fiberglass materials . . . . . . . 103
installations . . . . . . . . . . . . 34 To start the boiler . . . . . . . . . . . . . . 60
If boiler does not start correctly . . . . . . 60 Installation and service
Vent termination requirements . . 35 Check system and boiler after start-up . . 60 certificate . . . . . . . . . . . . . 104
4 Part number 550-142-056/0411

Please read before proceeding

Failure to adhere to the guidelines on this
Hazard definitions page can result in severe personal injury,
The following defined terms are used throughout this manual to death or substantial property damage.
bring attention to the presence of hazards of various risk levels or
to important information concerning the life of the product. When servicing boiler —
• To avoid electric shock, disconnect electrical supply
Indicates presence of hazards that will cause severe before performing maintenance.
personal injury, death or substantial property dam- • To avoid severe burns, allow boiler to cool before
age. performing maintenance.
Indicates presence of hazards that can cause severe • This boiler contains ceramic fiber and fiberglass
personal injury, death or substantial property dam- materials. Refer to the WARNING and instructions
on page 103.
age.
Indicates presence of hazards that will or can cause Boiler operation —
minor personal injury or property damage. • Do not block flow of combustion or ventilation air
to boiler.
Indicates special instructions on installation, op- • Should overheating occur or gas supply fail to
eration or maintenance that are important but not shut off, DO NOT turn off or disconnect electrical
related to personal injury or property damage. supply to circulator. Instead, shut off the gas supply
at a location external to the appliance.
• Do not use this boiler if any part has been under
water. Immediately call a qualified service techni-
Installer— Read all instructions, including this cian to inspect the boiler and to replace any part of
manual and all other information shipped with the the control system and any gas control that has been
boiler, before installing. Perform steps in the order under water.
given.
Combustion air —
User — This manual is for use only by a qualified • DO NOT install combustion air intake where there
heating installer/service technician. Refer to User’s is a risk of combustion air contamination.
Information Manual for your reference.
Carbon monoxide detector —
User — Have this boiler serviced/inspected by a
qualified service technician, at least annually. • For Direct Exhaust units, a carbon monoxide detec-
tor is required in the boiler room. The carbon mon-
Failure to comply with the above could result in oxide detector must be wired on the same electrical
severe personal injury, death or substantial property circuit as the boiler.
damage. • For Direct Vent units, a carbon monoxide detector
that is wired on the same electrical circuit as the boiler
Write in the CP number in the space provided on is strongly recommended.
the Installation certificate on page 104 if not already
shown. Boiler water —
When calling or writing about the boiler— Please • Thoroughly flush the system (without boiler con-
nected) to remove sediment. The high-efficiency heat
have the boiler model number from the boiler rating exchanger can be damaged by build-up or corrosion
label and the CP number from the boiler jacket. due to sediment.
Consider piping and installation when determining • Do not use petroleum-based cleaning or sealing
boiler location. compounds in boiler system. Gaskets and seals in the
system may be damaged. This can result in substantial
Any claims for damage or shortage in shipment property damage.
must be filed immediately against the transportation • Leaks in boiler or piping must be repaired at once
company by the consignee. to prevent make-up water. Use this boiler ONLY
in a closed-loop system. Continual fresh make-up
water will reduce boiler life. Mineral buildup in heat
exchangers reduces heat transfer, overheats the mate-
Commonwealth of Massachusetts rials, and causes failure. Addition of oxygen carried in
by make-up water can cause internal corrosion.
When the boiler is installed within the Commonwealth of Mas-
• Do not add cold water to hot boiler. Thermal shock
sachusetts, comply with the following. can cause heat exchanger to crack.
• This product must be installed by a licensed plumber or gas
fitter. Freeze protection fluids —
• NEVER use automotive or standard glycol antifreeze.
• If antifreeze is used, a reduced pressure back-flow preventer Use only freeze-protection fluids made for hydronic
device shall be used. systems. Follow all guidelines given by the antifreeze
• If sidewall vent or vent/air is installed, see instructions on manufacturer. Thoroughly clean and flush any re-
page 34. placement boiler system that has used glycol before
installing the new boiler.
Part number 550-142-056/0411 5

Prepare boiler location

Installations must follow these codes: Figure 1 Estimated GWC input at altitude
• Local, state, provincial, national codes, laws, regulations and ordinances.
• National Fuel Gas Code, ANSI Z223.1- latest edition. Altitude
% Sea level input
• Standard for Controls and Safety Devices for Automatically Fired Boil- (feet)
ers, ANSI/ASME CSD-1, when required. 1,000 97
• National Electrical Code. 2,000 93
• For Canada only: B149.1 or B149.2 Installation Code and CSA C22.1 3,000 90
Canadian Electrical Code Part 1 and any local codes. 4,000 87
The GWC boiler gas manifold and controls met safe lighting and other 5,000 83
performance criteria when boiler underwent tests specified in ANSI Z21.13 5,500 82
— latest edition.
6,000 80
For the Commonwealth of Massachusetts, read and follow 7,000 77
the special instructions located on page 34 of this manual. 8,000 74
9,000 72
Install the boiler so control system components are protected
10,000 69
from dripping or spraying water or rain during operation.
Allowing these components to become wet could cause a
boiler failure, resulting in severe personal injury, death or
Figure 2 Service clearances (recommended)
substantial property damage.
High altitude installations

GWC boiler controls automatically reduce input with increasing altitude.
See Figure 1 for estimated input at altitude as a percentage of sea level
input. Multiply the boiler sea level input by this percentage to obtain the
estimated high altitude input. Note that the length of the venting system
will also have a minor impact on input.
No modifications to the boiler should be necessary for installations up to
5,500 feet above sea level. For higher elevations, the air pressure switch
must be changed to a special high altitude switch. Refer to the high altitude
kit instructions, page 10. Note that the gas valve outlet pressure must be
checked (and adjusted if necessary) following instructions on page 60.
DO NOT sidewall vent DIRECT EXHAUST APPLICATIONS
at altitudes above 5,500 feet. Sidewall venting is only allowed
for DIRECT VENT applications (ducted combustion air) at
altitudes above 5,500 feet.
Vent length also affects boiler input — the boiler automati-
cally derates to compensate for pressure loss through the vent.
See the derate values given in Figure 105, page 99. For high
altitude installations, multiply the % in Figure 1 times the
value shown in Figure 105 to determine input vs sea level.
Service clearances
When possible, install GWC boilers with clearances at least as large as shown
in Figure 2 for best service access.
Flooring
The GWC boiler is approved for installation on combustible flooring, but
must never be installed on carpeting.
Do not install boiler on carpeting even if foundation is used.
Fire can result, causing severe personal injury, death or sub-
stantial property damage.
6 Part number 550-142-056/0411

Prepare boiler location (continued)

Foundation Figure 4 Minimum clearances — when
Provide a solid brick or concrete foundation pad if any of the following clearances are less than recom-
mended service clearances of Fig-
is possible: ure 2, page 6, install as shown below:
• When the floor can become flooded.
• When the boiler mounting area is not level.
• When a high-profile condensate pump is used, provide a foundation
high enough that the GWC condensate connection is at least as high
as the condensate pump inlet connection.
Figure 3 Minimum foundation dimensions (inches)
Boiler model W L H*
GWC-070
16 30¾ 2
GWC-105
GWC-140
16 37¾ 2
GWC-175
A Area adjacent to access door must be accessible
and must allow for removal of the GWC boiler
* Increase height if needed to ensure for service.
condensate trap outlet tee is above inlet No other appliance or air mover (exhaust fan,
of condensate pump, when used. etc.) may be mounted in the same space.
B Access DOOR with fresh air openings
C Provide (2) Fresh air openings — Each with at
Residential garage installation least 1 sq. inch per 1,000 Btuh of boiler input
Precautions
Take the following special precautions when installing the boiler in a
residential garage. If the boiler is located in a residential garage, per ANSI
Z223.1, paragraph 5.1.9:
• Mount the boiler a minimum of 18 inches above the floor of the
garage to assure the burner and ignition devices will be no less than
18 inches above the floor.
• Locate or protect the boiler so it cannot be damaged by a moving
vehicle.
Minimum clearances
You can install GWC boilers in spaces smaller than Fig-
ure 2, page 6 recommended service clearances, but never
smaller than shown in Figure 4. NOTICE SPECIAL REQUIREMENTS
FOR AIR OPENINGS: For installations
Installations with clearances less than shown in Fig- with clearances less than recommended
ure 2, page 6 must have air openings sized and located as service clearances (Figure 2, page 6), but
shown in Figure 4. no less than shown in Figure 4 — An
• Always provide at least screwdriver clearance to jacket front panel screws access door must be provided, fitted with
for removal of front panel for inspection and minor service. two air openings as shown in Figure 4.
• If the boiler cannot be serviced in place, pipe the boiler with unions Each opening must have a free area no
and isolation valves so it can be slid out of the space and serviced in less than 1 square inch per 1000 Btuh
an adjacent area. input of the GWC boiler in the space.
DO NOT apply the air opening sizes
• The space has to be equipped with a door so boiler can be accessed, given in Figure 42, page 36 or Fig-
unpiped and removed. ure 56, page 48.
Part number 550-142-056/0411 7

Prepare the boiler (continued)

Check orifice plate — replace if necessary Figure 5 Check for correct gas orifice plate
The correct orifice plate must be used. Failure to do so A Remove jacket front
will result in severe personal injury, death or substantial panel to access the bot-
property damage. The boiler is shipped with a natural tom side of the blower
gas orifice plate. It MUST BE CONVERTED to use housing.
propane. B Complete the propane
conversion label includ-
Natural gas: ed with the conversion
For natural gas installations, inspect the silver gas/air orifice plate kit. Install label on jacket
left side, as shown.
marking. It must be the same as the boiler size. If the orifice plate is
stamped with another size, obtain the correct plate from your whole- Leave the boiler on its back,
saler. The boiler size is stamped where the “X” is shown in the plate on the skid as shown, until
stamping, Figure 6. you have checked the gas/air
orifice plate and replace it if
necessary.
Propane:
For propane installations, replace the silver gas/air orifice plate with
the red/white plate, per following instructions. Ensure the red/white
plate boiler size is correct for the GWC boiler being installed. The boiler
size is stamped where the “X” is shown in the plate stamping, Figure 6. Figure 6 Follow instructions to check or replace
gas orifice plate ("X" = boiler size)
Also fill out the propane label in the conversion kit and attach to the
left side of the jacket, above the gas inlet opening, as shown in Figure 5.
Orifice plate installation, when required

Access the bottom of the blower housing as shown in Figure 5.
To inspect the plate only, read the marking on the plate edge. It
must read the same as the boiler size and fuel, as follows:
Boiler model Natural gas marking Propane marking

GWC-070 NG 3 SEC LP 3 SEC
To replace the plate, using a manual screwdriver or nut driver, see

Figure 6:

1. Loosen screws 1 and 2 two full turns.
2. Remove screws 3 and 4.
3. Pull the gas/air orifice plate forward to remove it.
4. Slide in the new plate as shown in Figure 6. The red side of a
propane plate must go next to the blower housing.
5. Replace screws 3 and 4. Tighten all four screws securely and uni-
formly. DO NOT overtighten. DO NOT exceed 40 inch-pounds
torque.
1–4 Screws — follow instructions for loosening and tightening
6. Bend down plate label tab at score mark as shown in lower right
5 Gas/air manifold
corner of Figure 6, item 10.
6 Front section, bottom view, component details omitted
DO NOT use electric or pneumatic screwdrivers to re- 7 Side shown must point toward air inlet hose — WARNING
move or tighten the gas/air boss screws. Hand-tighten label side for natural gas; WHITE side for propane gas
only, using manual screwdriver. Should the torque exceed 8 Propane orifice plate, RED one side and WHITE on the
40 inch-pounds, the threaded holes could strip out, other (red side must face the blower housing
causing an inadequate seal of the orifice plate. Failure to 9 Natural gas orifice plate, SILVER
properly seal the plate to the housing could result in a gas 10 Orifice plate after bending along score mark — label is
leak, causing severe personal injury, death or substantial visible when installed
property damage.
8 Part number 550-142-056/0411


Install condensate trap Figure 7 Install condensate trap
1. Before placing the boiler in position, install the condensate trap
line, shown in Figure 7. Items shown are provided with the boiler.
Step 1 Attach the flue drain hose (C) to the in-line flue drain
nipple (B).
Step 2 Slide a screw driver or pencil through the condensate
drain nipple (G).
Slide the end of the screwdriver or pencil into the open
end of the flue drain hose (C).
Feed the in-line flue drain (A) assembly into the flue con-
nection (D), guiding the flue drain hose through the con-
densate drain nipple (G) with the screwdriver or pencil.
Step 3 Press the in-line flue drain (A) into the flue connection
(D) and through the seal ring until it reaches the stop.
Then tighten the flue connection hose clamp to secure.
The flue drain hose (C) should now extend down past the
end of the condensate drain nipple (G).
Step 4 Slide the U-clamp (F) over the condensate trap tee (E)
and into the two holes in the rail. Attach the two nuts pro-
vided to the U-clamp and tighten to secure the condensate
trap tee to the rail.
A In-line flue drain Finished assembly
Step 5 Slide the ends of the condensate trap hose (H) onto the B Flue drain nipple
condensate drain nipple (G) and the condensate trap tee
C Flue drain hose
(E). Secure the condensate trap hose at each end with the
hose clamps (J). D Flue connection
E Condensate trap tee
Check the height of the condensate trap tee outlet. F U-clamp and nuts (not
Before rotating the boiler into position, measure the shown)
distance from the condensate tee outlet to the bottom G Condensate drain
of the boiler mounting rails. When the boiler is place in nipple
position, the condensate tee outlet must be higher than H Condensate trap hose
the condensate pump inlet connection (when a con- J Hose clamps
densate pump is used). Increase the foundation height
if necessary.
Part number 550-142-056/0411 9


Install high altitude air pressure switch Figure 8 Air pressure switch mounting
when required (only above 5,500 feet)
1. For installations at altitude more than 5,500 feet above sea level:
a. A special high altitude air pressure switch is required.
b. The gas valve outlet pressure setting must be checked, and
adjusted if necessary, per the instructions on page 60.
Failure to check gas valve outlet pressure and adjust, if
necessary, could result in severe personal injury, death
or substantial property damage. Carefully follow the
guidelines given in this manual.
2. Obtain the GWC high altitude kit from your local Williamson-
Thermoflo distributor. The high altitude kit contains the high 1 Interior panel top
altitude air pressure switch. 2 Jacket left side panel
3. See Figure 8 (switch shown with wires removed). 3 Air pressure switch
a. Remove the two (RED) control wires from the air pressure 4 WHITE hose
switch spade terminals. 5 RED hose
b. Remove the factory-installed air pressure switch (loosen top 6 Mounting screws
screw and remove bottom screw holding switch to jacket in-
terior panel).
c. Install the high altitude air pressure switch in the same loca-
tion.
d. Carefully replace the hoses on the new switch, with the red hose
on the hose barb closest to the electrical spade connectors, as Figure 9 Follow instructions to perform the steps
shown in Figure 8. The white hose goes on the other hose barb. shown below
e. Replace the two (RED) control wires on the new pressure
switch spade terminals.
Rotate the boiler into position

Boiler is shipped on back side. It must be taken off skid
and rotated into correct position.
After installing condensate line, inspecting (replacing if necessary) the
gas/air orifice and installing the high altitude kit (if required), move
the boiler near its position.
Figure 9 shows the boiler with the front and top panels replaced.
These panels may be left off if desired until the installation has been
completed.
Boiler is heavy and contains some sheet metal parts which
may have sharp edges. Wear gloves when handling and
take proper precautions when moving. Failure to do so
will result in severe personal injury, death or substantial
property damage.
Refer to Figure 9 for placement sequence as follows:
1 Wear heavy gloves — carefully rotate the boiler over onto its
base rail legs.
2 Clip the shipping strap securing the skid to the boiler block as-
sembly. Remove the skid and strap.
3 Attach the jacket rear panel as shown using (4) #10 x ½” screws
provided in the accessory bag.
10 Part number 550-142-056/0411


Perform hydrostatic pressure test Figure 10 Piping connections for hydrostatic test
Pressure test boiler before attaching water or gas piping (except as
noted below) or electrical supply. Remove jacket top panel before
proceeding.
Use two wrenches when tightening water piping at
boiler, using one of the wrenches to prevent the boiler
interior piping from turning. Failure to support the boiler
piping connections to prevent them from turning could
cause damage to boiler components.
Prepare boiler for test — see Figure 10

Step 1 Connect a hose from water supply to fill and drain boiler
for hydrostatic test. Hose is not included with boiler.
Step 2 Connect hose to boiler drain valve. Make sure hose can
also be used to drain boiler after test.
Step 3 Remove 1" nipple, 1" tee, bushing and pressure/tempera-
ture gauge from accessory bag. Pipe to boiler supply con-
nection as shown. Use pipe dope sparingly.
Step 4 Connect a nipple and shutoff valve to system supply
connection on the 1" tee. This valve will be used to bleed
air during the fill. Valve and nipple are not included with
boiler.
Step 5 Connect a nipple and shutoff valve to system return
connection at circulator flange. This valve will be used to
bleed air during the fill. Valve and nipple are not included
with boiler.
Step 6 Install a ¾" pipe plug in the relief valve opening, top of
the rear boiler section, as shown. Plug is not included with
boiler.
Fill and pressure test

1. Connect fill water supply through drain valve, item 2.
2. Fill boiler with water (be sure bleed valves at 4 and 5 are open).
3. When water flows from bleed valves, shut off water at drain
valve.
4. Close bleed valves.
5. Slowly reopen drain valve (item 2) until test pressure of 45 PSIG
(or 1.5 times boiler relief valve setting — NEVER MORE than
75 PSIG) is reached on the pressure gauge.
6. Test at this pressure for no more than 10 minutes.
Do not leave boiler unattended. If the boiler is filled with
cold water, the water can absorb heat from the room and
expand, causing excessive pressure, resulting in severe Drain and remove fittings
personal injury, death or substantial property damage.
1. Disconnect fill water hose from water source.
7. Make sure constant gauge pressure has been maintained through-
out test. Check for leaks. Repair if found. 2. Drain boiler at drain valve or out hose, whichever pro-
vides best access to drain. Close drain valve and remove
Leaks must be repaired at once. Failure to do so can dam- hose after draining.
age boiler, resulting in substantial property damage.
3. Remove nipples and valves at 4 and 5 unless they will
Do not use petroleum-based cleaning or sealing com- remain for use in the system piping.
pounds in boiler system. Severe damage to boiler will
occur, resulting in substantial property damage. 4. Remove plug (item 6) from relief valve tapping.
Part number 550-142-056/0411 11

Install water piping

Use two wrenches when tightening water piping at Air separator
boiler, using one of the wrenches to prevent the boiler
interior piping from turning. Failure to support the boiler Install an air separator in the piping as shown in this
piping connections to prevent them from turning could manual. For single-zone systems, install the air separator
cause damage to boiler components. in the return piping as shown in Figure 14, page 14. This
allows mounting the automatic air vent and expansion tank
The cast iron heat exchanger return temperature must off of the separator.
be kept at or above 140°F during all times of operation
to prevent possibility of corrosion due to condensation. Install relief valve
This is done automatically, using the boiler's internal 1. Install relief valve ONLY as shown in Figure 12.
circulators. DO NOT remove or tamper with these cir-
culators. Failure to comply could result in severe personal 2. Connect discharge piping to safe disposal location, fol-
injury, death or substantial property damage. lowing guidelines in Figure 13, page 13.
General piping information Figure 12 Install and pipe relief valve
Minimum pipe size for boiler loop piping
Figure 11 Provide boiler loop piping no smaller than listed

below (based on 20°F temperature rise)
Boiler loop pipe size, Minimum

GWC-070 or 105 1”
GWC-140 or 175 1¼”
Additional limit controls

Following standard industry practices, if installation is to comply with
ASME or Canadian requirements, an additional high temperature
limit may be needed. Consult local requirements for other codes/
standards to determine if needed. Wire as shown in Figure 63, page 54.
• Install a manual reset high temperature limit between the boiler
and the isolation valve.
• Wire the manual reset limit in series with the boiler limit con-
trol.
• Set the manual reset limit control at least 20°F above the boiler
limit control setting (maximum setting 220°F).
Low water cut-off, when required

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 water installations. Electrode probe-
type is recommended. Purchase and install in tee in supply piping above
boiler. Wire contact as shown in Figure 63, page 54. Legend
If boiler is connected to heating coils located in air han- 1 Jacket plug for unused relief valve jacket open-
dling units where they can be exposed to refrigerated ing.
air, use flow control valves or other automatic means to 2 Jackets are provided with two relief valve open-
prevent gravity circulation during cooling cycle. Circu- ings because each jacket size is used for two boiler
lation of cold water through the boiler could result in sizes. Cover the unused opening with the plug
damage to the heat exchanger, causing possible severe provided.
personal injury, death or substantial property damage. 3 Boiler relief valve (from accessory bag)
4 ¾” x 3” nipple, provided in accessory bag
Backflow preventer 5 ¾” relief valve tapping in back section
Where required by codes, install a backflow preventer in the cold 6 Connect minimum ¾” discharge piping to relief
water fill line, as shown in suggested piping diagrams on following valve.
pages. Install a check valve if a backflow preventer is not installed. See Figure 13, page 13.
12 Part number 550-142-056/0411

Install water piping (continued)

Figure 13 Relief valve installation guidelines Expansion tank
Figure 14, page 14 and Figure 15, page 14 show typical installation of the
To avoid water damage or scalding expansion tank. Always locate the air separator and expansion tank as
due to relief valve operation, as shown in the suggested piping drawings, beginning with Figure 17, page 16.
per local or state codes: Ensure that the expansion tank size will handle boiler and system water
volume and temperature. See tank manufacturer’s instructions and rat-
Discharge line must be connected ings for details. Additional tanks may be added to the system if needed to
to relief valve outlet and run to a handle the expansion. These tanks may be installed by connecting to tees
in the system piping.
safe place of disposal. Terminate the
discharge line in a manner that will Undersized expansion tanks cause system water to be lost
prevent possibility of severe burns from the relief valve and makeup water to be added through
or property damage should the valve the fill valve. Eventual section failure can result. Always locate
discharge. the cold water fill connection at the expansion tank. Never
locate this elsewhere in the system.
Discharge line must be as short as Diaphragm- or bladder-type tank:
possible and be the same size as the
valve discharge connection through- Refer to Figure 14, page 14 for suggested piping when using a diaphragm-
or bladder-type expansion tank.
out its entire length.
Diaphragm- or bladder-type expansion tank — Control
Discharge line must pitch downward fill pressure with the tank air charge pressure. Always check
from the valve and terminate at least pressure and charge tank with tank removed from system
6” above the floor drain where any to be sure reading is accurate. Boiler relief valve is set for 30
PSIG. Operating pressure of system, after temperature expan-
discharge will be clearly visible. sion above cold fill pressure, should not exceed 24 PSIG to
avoid weeping of relief valve.
The discharge line shall terminate
plain, not threaded, with a mate- Install an automatic air vent on top of the air separator, per separator
rial serviceable for temperatures of manufacturer’s instructions.
375°F or greater. Closed-type expansion tank:
Figure 15, page 14 shows suggested piping when using a closed-type expan-
Do not pipe the discharge to any sion tank, in which the air is directly in contact with tank water.
place where freezing could occur.
Connect piping (½” or ¾”) from the air separator top outlet to the tank
No shutoff valve shall be installed fitting. Slope any horizontal piping a minimum of 1 inch per 5 feet of
between the relief valve and boiler, horizontal pipe.
or in the discharge line. Do not Always use a tank fitting, such as the B&G Tanktrol or Taco Taco-Trol
plug or place any obstruction in the (shown). The fitting reduces gravity flow of water in the piping to the
discharge line. tank, avoids air bubbling through the tank water, and provides the proper
fill height in the tank.
Test the operation of the valve after Correct all leaks in the system or tank piping. Leaks allow
filling and pressurizing system by air to escape from the system and will cause water-logging
lifting the lever. Make sure the valve of the tank. This will result in water loss through the boiler
discharges freely. If the valve fails to relief valve due to over-pressurization.
operate correctly, replace it with a NEVER use an automatic air vent in a system equipped with a
new relief valve. closed-type expansion tank. The air removed from the system
will cause water-logging of the expansion tank.
Failure to comply with the above
Closed-type expansion tank — Follow tank manufacturer’s
guidelines could result in failure of instructions for filling the tank. Typical tank sizing provides
the relief valve to operate, resulting for approximately 12 PSIG when the tank is filled to the
in possibility of severe personal in- normal level and system water is cold. Note that boiler relief
jury, death or substantial property valve is set for 30 PSIG. Operating pressure of system, after
damage. temperature expansion above cold fill pressure, should not
exceed 24 PSIG to avoid weeping of relief valve.
Part number 550-142-056/0411 13


Figure 14 Piping to single-zone system using diaphragm- or Figure 15 Piping closed-type expansion tank
bladder-type expansion tank. Boiler connections are
1” NPT (supply from 1” tee, return to 1” recuperator
flange).
Pipe diaphragm- or bladder-type expansion tanks to the bot-

tom of the separator.
Pipe closed-type (air in contact with water) tanks to the top of
the air separator. Always connect the fill line to the expansion
tank location, as shown above and in the suggested piping.
Legend
1 Relief valve discharge piping — see page 12 6 Cold fill line, with backflow preventer or check valve
2 Isolation valves when required by codes (see Figure 15 for typical com-
ponents)
3 Fill valve
7 System supply piping
4 Diaphragm-type expansion tank — always locate as
shown in the suggested piping drawings in this manual 8 System return piping
5 Air separator 10 Pressure reducing valve, when used
• provide with automatic air vent ONLY when used 11 Quick-fill bypass valve, when used
with diaphragm-type expansion tanks 12 Closed-type expansion tank — always locate as shown
• pipe air outlet to expansion tank when used with in the suggested piping drawings in this manual
close-type tanks 13 Tank fitting
14 Part number 550-142-056/0411


System water piping methods Simplified pipe/circulator selection
Most piping methods shown in this manual use 1. Install the boiler and piping using the recommended piping
primary/secondary connection to the boiler loop. layouts in this manual.
These designs ensure proper flow through the GWC 2. Size the piping and components for each circuit in the space
boiler, for the most efficient and reliable operation heating system using Figure 16. At the flow rates listed, the
of the boiler and the heating system. For other head loss in all piping will be 0.04 feet per foot of pipe.
piping methods, consult your local Williamson- a. Determine the heating load (Btuh) for each circuit.
Thermoflo representative. b. Calculate the flow rate for each circuit using its load.
To use a 20°F temperature drop, just divide the
Circulators MBH (1,000’s of Btuh) by 10.
Example — Flow for 20°F temp drop with 35,000
Do not remove either of the GWC internal pumps Btuh:
for use elsewhere in the system. Both pumps are FLOW = 35 MBH / 10 = 3.5 gpm
required for proper operation. Removing a pump c. Find the pipe size in Figure 16 that has a max flow rate
will cause the boiler to malfunction. Substantial just larger than that required for the circuit.
property damage could result. d. Find the total equivalent length (TEL) of the circuit.
TEL accounts for losses through fittings and valves by
Never install another pump in series with the using the equivalent length of pipe that would cause
GWC boiler. Forced flow can cause improper op- the same head loss. Add these numbers to the measured
eration of the boiler controls. Substantial property length of the circuit to find TEL in feet.
damage could result. TEL is usually close to 1.5 times the length of the
Failure to comply could result in unreliable perfor- circuit for residential baseboard, radiator or convec-
tor applications.
mance and nuisance shutdowns from insufficient
flow. e. Measure the length of each circuit from the circulator
outlet back to its inlet. Then multiply this length times
1.5 to get the approximate TEL of the circuit.
Circulator flow rate f. Find the head loss for each circuit:
Size system circulators based on the flow rate required to achieve TEL = 1.5 X Circuit Length (feet)
the temperature change needed. You can closely estimate tem- HEAD = TEL X 0.04 (feet water column)
perature rise (or drop) through a circuit by using the following
formula, where TD is temperature rise (or drop), FLOW is flow g. NOTE: Size system header piping for the total flow of
all connected zones.
rate (in gpm), and BTUH is the heat load for the circuit:
3. Example:
BTUH
FLOW = —–—–—–—– a. For a circuit with heating load = 45,000 Btuh (= 45
TD x 500 MBH). Measured length of circuit is 88 feet.
Examples: b. Flow = 45 MBH / 10 = 4.5 gpm.
c. TEL = 1.5 x 88 feet = 132 feet.
Consider a system loop for a system with total heating load equal d. From Figure 16, select 1" pipe (max flow = 8 gpm).
to 210,000 Btuh. The desired temperature drop through the system
piping is 20°F. Then the required flow rate is: e. Head loss = TEL x 0.04 = 132 x 0.04 = 5.28 feet.
f. Select a circulator that can deliver at least 4.5 gpm at a
210,000 head of 5.28 feet. (Read the NOTICE below.)
FLOW = —–—–—–—– = 21 gpm
20 x 500 To use this method, limit the flow through ¾"
finned-tube baseboard to 3.9 gpm, or use 1" base-
SIMPLIFIED: For 20° temperature drop, FLOW = MBH / 10. board and limit flow to 7.1 gpm. If the total load
of the circuit requires more flow, split the circuit
Circulator head requirement into two or more.
The circulator must be capable of delivering the required flow
against the head loss that will occur in the piping. Determine Figure 16 Flow rates for 0.04 feet head loss per foot of
the pipe size needed and the resultant head loss using accepted copper pipe (based on water at140°F)
engineering methods. The simplified pipe sizing here is limited
to residential systems, and does not include systems with fan coil Pipe size MAX Flow rate (GPM) Pipe size MAX Flow rate (GPM)
units or radiant tubing. (inches) @ 0.04 feet per foot (inches) @ 0.04 feet per foot
The following simplified method for pipe and cir- ¾ 4 2 45

culator sizing must be limited to residential applica- 1 8 2½ 75
tions using baseboard (finned or cast iron), cast iron 1¼ 14 3 140
radiators or convectors. DO NOT apply for radiant
heating, fan coil units or commercial installations. 1½ 22 4 290
Part number 550-142-056/0411 15


Baseboard system piping — Figure 17 Baseboard system — circulator zoning
CIRCULATOR zoning (primary/secondary)
Apply Figure 17 for circulator zoning on systems using baseboard
heaters. The heaters can be any baseboard style, including finned tube
or cast iron.
Zoning with circulators — The GWC internal system
circulator cannot be removed from the boiler for use as
one of the zone circulators. It must remain as shipped
from the factory to allow proper flow control inside the
boiler. You will need a circulator for each zone. Provide
circulator relays or circulator zone controller.
Baseboard system piping —

ZONE VALVE zoning (direct connection)
The boiler internal circulator can be used to circulate many zone-valve
zoned systems as shown in Figure 18, page 17 for application on systems
using baseboard (finned tube or cast iron).
• DO NOT apply this piping when using a GWC-175 — the internal
circulator cannot supply enough flow to the system.
• When applying Figure 18, page 17, DO NOT exceed the limits MINIMUM
shown in Figure 19, page 17. Boiler loop pipe size
• For systems requiring higher flow or head loss, apply the GWC-070/105 1”
suggested piping of Figure 20, page 18, NOT that of Fig- GWC-140/175 1¼”
ure 18, page 17.
Balancing, when required — Substitute a memory-stop
valve for one of the isolation valves in each zone to use
the memory-stop valve for balancing flow as well as
isolation.
Legend
Zoning with zone valves — Provide a separate 24-volt
transformer to power the zone valves. Size the trans-
former to handle the total rated load of all connected zone 1 Isolation valves tor to tank fitting as in
Figure 15, page 14.)
valves. Alternatively, use a zone valve zone controller. 2 Automatic air vent (with
diaphragm-type expan- 5 Zone circulator
sion tank), or connect to 6 Flow/check valve
Applying Figure 18, page 17 tank fitting (closed-type
expansion tank). 7 Hose bibb purge valve
1. Figure 18, page 17 and Figure 19, page 17 provide guidelines for 8 Boiler pressure/tempera-
checking whether the GWC internal circulator can provide suffi- 3 Diaphragm- or bladder-
type expansion tank, if ture gauge
cient flow when directly connected to a two-pipe baseboard system. used. (For closed-type 16 Cold water fill line — see
The outputs of GWC boilers are all too high for con- expansion tank, pipe Figure 15, page 14 for
from top of air separa- typical components
nection to a single-loop series-loop system. To apply to
an existing series loop system, the system must be fitted
with trunk lines to convert to a split-loop system. Pro-
vide either one or two trunk lines to meet the minimum
number of circuits and maximum loading per circuit
given in Figure 19, page 17.
2. The system pipe sizing must be no smaller than shown in the
Legend for Figure 18, page 17.
3. Values shown for maximum circuit lengths, maximum load per
circuit and the maximum feet baseboard per circuit are limits that
ensure the internal circulator will have sufficient head to provide
the flow needed for each circuit.
16 Part number 550-142-056/0411


Figure 18 Zone valve zoning — GWC-070, GWC-105 or
GWC-140 (DO NOT apply to GWC-175)
Legend
1 Isolation valves 4 Zone valve

2 Automatic air vent (with 7 Hose bibb purge valve
diaphragm-type expan-
8 Boiler pressure/tempera-
sion tank), or connect to
ture gauge
tank fitting (closed-type
expansion tank). 10 Differential pressure by-
pass valve
3 Diaphragm- or bladder-
type expansion tank, if 16 Cold water fill line — see
used. (For closed-type Figure 15, page 14 for
expansion tank, pipe from typical components
top of air separator to
tank fitting as in Fig-
ure 15, page 14.)
Pipe sizes (NPT), minimum

Mains Circuits
Boiler model
GWC-070
1" ¾"
GWC-105
GWC-140 1¼" ¾"
Circuit requirements
See Figure 19
One-pipe diverter tees systems — The ap-

plication information on this page is based
on two-pipe baseboard systems. To check
whether the internal circulator can provide
sufficient flow to a one-pipe diverter tee
system, use the available head value given in
Figure 19, page 17.
Figure 19 The system must meet the following requirements when applying Figure 18
Boiler Circulator HEAD Maximum Minimum Max load Max feet baseboard Summary
model available to the circuit number of any of any circuit
system length of circuits circuit (@ 600 Btuh/foot)
L
6.5 GPM total
6.4 feet w.c.
GWC-070 103 feet 2 40 MBH 67 feet (max 4GPM any cricuit)
@ 6.5 GPM
20°F temperature drop
9.7 GPM total
4.1 feet w.c.
GWC-105 92 feet 3 33 MBH 55 feet (max 3.3 GPM any circuit)
@ 9.7 GPM
8.7 GPM
5.5 feet w.c.
GWC-140 * 112 feet 3 53 MBH 88 feet (max 3.5 GPM any circuit)
@8.7 GPM
GWC-175 DO NOT apply to GWC-175 — Use primary/secondary piping ONLY, as in Figure 20, page 18.
* This application may be marginal. It could cause temperature distribution problems, because the temperature drop is 30°F,
NOT 20°F. The best method is to use primary/secondary piping for the GWC-140 as in Figure 20, page 18.
Part number 550-142-056/0411 17


Radiator system piping Figure 20 Radiator system — zone-valve zoning
Apply Figure 20 (zone-valve zoning) or Figure 21 (circulator zoning)
to systems using standing cast iron radiators. This applies to gravity
water systems and converted steam systems using columnar, tubular
or recessed cast iron radiators.
The suggested piping for zone-valve zoning radiator systems differs
from baseboard systems because of the high water content of cast iron
radiators. The GWC internal circulators automatically regulate supply
and internal bypass flow based on the temperature of the water return-
ing to the boiler. At the start of many heating cycles in a radiator system,
the water in the radiators is cool. So the boiler would slow down system
flow rate while sending out relatively hot water. This could cause heat
distribution problems. Install a separate system circulator as shown
in Figure 20 when zoning with zone valves. The separate circulator
assures a relatively constant temperature drop through the system.
The boiler internal circulators must be left in the boiler. They cannot
be removed for use a zoning circulator. Provide a circulator for each
zone when circulator zoning, and pipe the system as in Figure 21.
isolation. MINIMUM
Boiler loop pipe size
Zoning with zone valves — Provide a separate 24-volt GWC-070/105 1”

GWC-140/175 1¼”
former to handle the total rated load of all connected zone
valves. Alternatively, use a zone valve zone controller.
one of the zone circulators. It must remain as shipped Figure 21 Radiator system — circulator zoning
The system circulator must be supplied by the in-
staller.
Legend
1 Isolation valves
2 Automatic air vent (with diaphragm-type expansion tank), or
connect to tank fitting (closed-type expansion tank).
3 Diaphragm- or bladder-type expansion tank, if used. (For closed-
type expansion tank, pipe from top of air separator to tank fitting
as in Figure 15, page 14.)
4 Zone valve
5 System or zone circulator
6 Flow/check valve
7 Hose bibb purge valve MINIMUM
8 Boiler pressure/temperature gauge Boiler loop pipe size
9 System supply temperature gauge GWC-070/105 1”

GWC-140/175 1¼”
10 Differential pressure by-pass valve
16 Cold water fill line — see Figure 15, page 14 for typical components
18 Part number 550-142-056/0411


Single-zone radiant heating or heat pump Figure 22 Single-zone radiant heating or
heat pump system
Radiant heating systems and heat pump systems usually require
system supply water temperatures below 140°F. But the boiler outlet
water temperature will be at least 150°F to 160°F during most operat-
ing conditions. So the piping must include a method of reducing the
supply water temperature to the system.
Figure 22 uses two balancing valves to manually adjust the supply water
temperature. Follow the instructions below to adjust these valves. Install
the supply temperature limit control (item 14) as shown to protect the
system from over-temperature conditions. Note also that this piping
requires a separate system circulator, as shown, because of the higher
flow rates of radiant and heat pump systems.
Manual adjustment of the supply temperature is limited to single-

zone systems because multi-zone systems will cause varying loads,
making it unlikely an acceptable valve setting could be found. See
Figure 23, page 20 or Figure 24, page 20 for multi-zone systems.
You may also apply the suggested piping of either Figure 23, page 20 or
Figure 24, page 20 if you want automatic supply temperature regulation
MINIMUM
or outdoor reset temperature control. Boiler loop pipe size
GWC-070/105 1”
For additional information and alternatives in piping for radiant heat- GWC-140/175 1¼”
ing systems, contact Williamson-Thermoflo.
The system circulator must be supplied by the in-

staller.
Adjust balancing valves Legend

Use valves 17 and 18 to mix boiler supply water with system return 1 Isolation valves
water, reducing supply water temperature to the system.
2 Automatic air vent (with diaphragm-type expansion
1. Subtract the design system supply temperature from 150°F. Call tank), or connect to tank fitting (closed-type expan-
this number the temperature difference. sion tank).
2. Open valve 17 and close valve 18. 3 Diaphragm- or bladder-type expansion tank, if used
3. Start the boiler and system. (For closed-type expansion tank, pipe from top of air
separator to tank fitting as in Figure 15, page 14.)
4. Let the system warm up for about 15 minutes.
5 System circulator
5. Note the temperature at gauge 9 (system supply) and gauge 8
(boiler supply). 7 Hose bibb purge valve
6. Slowly close valve 17 while opening valve 18 until gauge 9 reads 8 Boiler pressure/temperature gauge
lower than gauge 8 by at least the temperature difference found
9 System supply temperature gauge
in step 1.
10 Return temperature gauge
7. Example: For a design supply temperature of 100°F, the tempera-
ture difference would be 150°F minus 100°F, or 50°F. Set the valves 14 Supply temperature limit control — Set at a tempera-
until gauge 9 reads at least 50°F lower than gauge 8. ture below the maximum allowed for the system or as
directed by the system designer.
16 Cold water fill line — see Figure 15, page 14 for typical
components
17 Balancing valve
18 Balancing valve
Part number 550-142-056/0411 19


Multi-zone radiant heating system Figure 23 Auto system supply temp regulation —
Multi-zone systems require automatic regulation of the system sup- zone valve zoning
ply temperature because of widely varying load conditions. Figure 23
(zone-valve zoning) and Figure 24 (circulator zoning) show suggested
piping for these systems.
Provide an automatic temperature control valve or
motor-operated valve which can be adjusted for the
desired supply water temperature. This is required to
protect the radiant system from excessive temperature.
Zone-valve zoning — The suggested piping uses a separate circulator
for system circulation to provide the higher flow typical of radiant
heating systems and to assure good temperature distribution in the
system when the return water temperature is low.
Circulator zoning — The GWC internal circulators must not be re-
moved. Provide a separate circulator for each zone.
isolation.
transformer to power the zone valves. Size the trans- MINIMUM
former to handle the total rated load of all connected zone Boiler loop pipe size
valves. Alternatively, use a zone valve zone controller. GWC-070/105 1”
Zoning with circulators — The GWC internal system GWC-140/175 1¼”
circulator relays or circulator zone controller. The sys- Figure 24 Auto system supply temp regulation —
tem circulator must be supplied by the installer. circulator zoning
Outdoor reset
Apply Figure 23 or Figure 24 for any system intended for outdoor reset
of the supply water temperature. Use a motor-operated three-way valve
and an outdoor reset temperature control system.
Legend
1 Isolation valves
3 Diaphragm- or bladder-type expansion tank, if used (For closed-
4 Zone valve
6 Flow/check valve
7 Hose bibb purge valve
8 Boiler pressure/temperature gauge
9 System supply temperature gauge MINIMUM
Boiler loop pipe size
10 Supply temperature automatic mixing valve
11 Differential pressure by-pass valve GWC-070/105 1”
GWC-140/175 1¼”
16 Cold water fill line — see Figure 15, page 14 for typical components
20 Part number 550-142-056/0411


Piping snow melt systems or combination Figure 25 Auto return temp regulation — circulator
snow melt/space heating systems zoning
Combination snow melt/space heating systems can have return water

temperature below 60°F, and the return temperature will fluctuate. So
these systems require automatic return water temperature as shown in
Figure 25 (zone-valve zoning) or Figure 26 (circulator zoning).
Select an automatic temperature control valve or motor-operated valve
which can be adjusted to provide a return water temperature of at least
60°F. Any setting higher than 60°F will also be acceptable.
Zone-valve zoning — The suggested piping uses a separate circulator
for system circulation to assure good temperature distribution in the
system when the return water temperature is low.
Circulator zoning — The GWC internal circulators must not be re-
moved. Provide a separate circulator for each zone.
The return water temperature to the boiler must be
at least 60°F. Provide and apply means to regulate the
return temperature. Failure to do so can result in boiler
control operation problems, causing possible significant
property damage.
Zoning with zone valves — Each zone in the piping MINIMUM
diagrams in this section is shown with an isolation valve Boiler loop pipe size
on each side. Substitute a memory-stop valve for one of GWC-070/105 1”
these in each zone in order to use the memory-stop valve GWC-140/175 1¼”
for balancing flow as well as isolation.
Provide a separate 24-volt transformer to power the zone
valves. Size the transformer to handle the total rated load
of all connected zone valves.
Zoning with circulators — The GWC internal system Figure 26 Auto return temp regulation — zone valve
circulator cannot be removed from the boiler for use as zoning
circulator relays or circulator zone controller. The sys-
tem circulator must be supplied by the installer.
Legend
1 Isolation valves
3 Diaphragm- or bladder-type expansion tank, if used (For closed-
4 Zone valve
6 Flow/check valve
7 Hose bibb purge valve
9 System supply temperature gauge
MINIMUM
10 Return temperature automatic mixing valve Boiler loop pipe size
11 Differential pressure by-pass valve GWC-070/105 1”

16 Cold water fill line — see Figure 15, page 14 for typical components GWC-140/175 1¼”
Part number 550-142-056/0411 21


Water chiller systems Figure 27 Installing GWC boiler in system with water
Pipe the boiler and water chiller as shown in Figure 27. chiller
Install boiler, as shown, so chilled medium is piped in parallel with
heating boiler.
Use appropriate valves to prevent chilled medium from entering boiler.
See Figure 27 for typical installation of balancing valve and check valve.
Install the flow/check valve in the boiler supply piping, as shown in
Figure 27, to prevent gravity circulation during the cooling cycle.
If boiler is connected to heating coils located in air handling units where
they can be exposed to refrigerated air, use flow control valves or other MINIMUM
automatic means to prevent gravity circulation during cooling cycle. Boiler loop pipe size
Balancing, when required — Substitute a memory-stop GWC-070/105 1”

GWC-140/175 1¼”
isolation.
former to handle the total rated load of all connected zone
valves. Alternatively, use a zone valve zone controller.
Chilled water systems often use closed-type expansion
tanks, as shown in Figure 27. DO NOT install automatic
air vents on these systems. Legend
1 Isolation valves
2 Air separator
3 Expansion tank with tank fitting (piping shown for
application of a closed-type expansion tank)
5 System circulator
6 Flow/check valve
components
17 Balancing valve
19 Chiller
20 Strainer
21 Check valve
22 System supply
23 System return
22 Part number 550-142-056/0411

Multiple boiler installations

Placing multiple boilers Figure 28 Side-to-side mounting of multiple GWC boilers, showing
1. Locate multiple boilers in boiler room according RECOMMENDED clearances
to:
a. Figure 28 (side-to-side), or
b. Figure 29 (back-to-back).
2. Provide the clearances indicated in the illustrations
listed above to provide for access and servicing. If
these recommended dimensions are not possible,
provide at least the recommended service clearances
given on page 6. Also follow local codes.
3. Construct boiler foundation if boiler room floor
is uneven or if there is a danger of flooding. Size
foundation to allow for clearance and spacing di-
mensions shown in the illustrations at right.
4. Chalkline boiler locations on foundation or boiler
room floor.
5. Uncrate, assemble and mount boilers according to Figure 29 Back-to-back installation of multiple GWC boilers,
instructions in this manual. showing RECOMMENDED clearances
6. Provide clearance for installation of venting, air
piping, gas piping, expansion tank, primary circula-
tor and other accessories.
Controlling multiple GWC boilers

1. Multiple GWC boilers can be controlled using any
boiler control/sequencing system that provides an
isolated contact for call for heat (connected to the
boiler's T-T terminals).
Piping multiple GWC boilers

1. See suggested piping diagrams in this manual.
Contact Williamson-Thermoflo for assistance for
systems not covered.
2. Always pipe the boilers on a secondary loop in a
primary/secondary circuit as shown in the examples
in this manual.
Part number 550-142-056/0411 23

Multiple boiler water piping

Secondary header piping installation
Maximum connected load per header:
1. Main header and secondary header pipe sizing. 2-inch header — 450 MBH
a. New system — See page 15. 3-inch header — 1400 MBH
b. Replacing boilers in an existing system — Without reducing 4-inch header — 2900 MBH
size, connect system supply and return lines. Install tees or
crosses for secondary headers as shown in Figure 30 or Fig-
ure 31. Size headers to handle total connected boiler output
as shown. Figure 30 Single-sided secondary header, typical
2. Provide connections in main header for secondary headers as close
as possible to the midpoint of multiple boilers.
a. Use tees for four or less boilers, as in Figure 30.
b. Use either tees (Figure 30) or crosses (Figure 31) for five or
more boilers.
3. Secondary header placement:
a. To alternate spacing for supply and return lines to boilers,
reverse the short-end and long-end of the headers as shown
in Figure 30 and Figure 31.
b. Return header must be on the return side of the main and sup-
ply header must be on the supply side of the main. Drawings
in this manual show flow in system main from right to left.
For system flowing left to right, reverse the locations of the
manifolds accordingly.
4. Connect from secondary header branches to boiler supply and
return connections using copper or steel pipe, sized for the re-
quired flow rate.
5. Provide a flow/check valve in the supply piping of each boiler as
shown in piping diagrams in this manual. Install an isolation valve
on the supply and return of each boiler as shown. Some local codes
may require the use of individual water level controls and limits
on each boiler when isolation valves are installed.
6. Install main system air eliminator and primary circulator in sup- Figure 31 Double-sided secondary header, typical
ply piping as shown in piping diagrams. Place expansion tank on
suction side of system circulator as shown.
7. Install system accessories as shown in drawings.
8. Piping recommendation drawings:
a. Figure 30 and Figure 31 show details of secondary headers.
b. Figure 32, page 25 is a schematic piping drawing showing the
locations of typical boiler piping and system piping, including
limits and other devices often required by local codes.
c. Figure 33, page 26 and Figure 34, page 27 are three-dimensional
piping drawings of typical multiple boiler installation.
d. Figure 35, page 28 shows recommended piping when an isolat-
ing heat exchanger is needed.
9. If desired, other primary/secondary piping arrangements can be
used.
When using isolation valves on each boiler, some codes
may require providing a low water control and additional
limit for each boiler. Consult local codes to determine
if omission of the individual boiler isolation valves may
allow the use of a single water level control and additional
limit for the entire multiple boiler system.
24 Part number 550-142-056/0411

Multiple boiler water piping (continued)

Figure 32 Piping schematic — typical for multiple GWC boilers, using secondary headers
Legend — Figure 32
1 Flow/check valve (each boiler) 11 Check valve or backflow preventer, as required by applicable
codes
2 Isolation valves (when used)
12 Isolation valve
3 Cap
13 Water flow switch (when used)
4 Secondary header (supply) — layout and size per
page 24 14 Supply water temperature control (when used)
5 Secondary header (return) — layout and size per 15 Low water cutoff (when used) (place above primary header)
page 24
components
6 Primary circulator
18 System supply
7 Expansion tank (diaphragm type)
19 System return
8 System air eliminator
20 (Not shown) Boiler relief valve and discharge piping, installed
9 System automatic air vent per GWC Boiler Manual
10 Pressure reducing valve 30 Long end of secondary header
Part number 550-142-056/0411 25


Figure 33 Piping layout — typical for multiple GWC boilers, using secondary headers (2-boiler system)
1 Flow/check valve (each boiler) 17 3-way diverting valve (operated by DHW aquastat — valve end
2 Isolation valves (when used) switch connects across boiler thermostat terminals)
3 Caps 18 System supply
4 Secondary header (supply) — layout and size per page 24
19 System return
5 Secondary header (return) — layout and size per page 24
6 Primary circulator 20 Boiler relief valve and discharge piping, installed per GWC Boiler
7 Expansion tank (diaphragm type) Manual
8 System air eliminator 21 Indirect-fired storage water heaters — Example is shown connect-
9 System automatic air vent ed to one boiler of the system. The indirect water heater could
16 Cold water fill line — see Figure 32, page 25 for typical com- also be connected with a secondary connection off the main
ponents header, as in Figure 34, page 27.
26 Part number 550-142-056/0411


Figure 34 Piping layout — typical for multiple GWC boilers, with DHW storage heaters (4-boiler system)
Flow rate Size Flow rate Size

Suggested DHW
boiler-side pipe 1 – 4 gpm ¾” 22 – 45 gpm 2”
sizing (for max 0.04 4 – 8 gpm 1” 45 – 75 gpm 2½”
feet head loss per foot of
total equivalent length, 8 – 14 gpm 1¼” 75 - 140 gpm 3”
TEL)
14 – 22 gpm 1½” 140 – 290 gpm 4”
1 Flow/check valve (each boiler) 21 Indirect-fired storage water heaters — Example is shown with a boiler This piping is sug-
2 Isolation valves (when used) water circulator on each water heater. Alternatively, the water heaters could gested only. The
3 Caps be connected with reverse return piping, using a common circulator. layout above should be controlled
4 Secondary header (supply) — layout and size 22 Boiler water inlet with a boiler sequencing panel that
per page 24 23 Boiler water outlet provides DHW operation as well.
24 DHW boiler-side circulators
Wire the heating system circulator
5 Secondary header (return) — layout and size
to operate only on call for heat. Al-
per page 24 25 DHW boiler-side return secondary header
ternatively, use the boiler sequencing
6 Primary circulator 26 DHW boiler-side supply secondary header panel to provide domestic priority
7 Expansion tank (diaphragm type) 27 Flow/check valves (to prevent induced or gravity flow in heating system or by disabling the heating system cir-
8 System air eliminator DHW piping) culator any time there is a DHW call
9 System automatic air vent 28 Check valve to prevent heat migration in heating system for heat. The boiler internal circula-
16 Cold water fill line — see Figure 32, page 25 29 Drain valves tors operate on any call for heat,
for typical components 30 Sensor for BCP (boiler control panel), when used whether heating system or DHW.
Offset the DHW boiler-side supply
18 System supply Note: See water heater manual for DHW piping — The DHW piping must also and return manifolds as shown so
19 System return be manifolded together since the boiler-side piping is manifolded. If DHW the total run of pipe and fittings to
20 Boiler relief valve and discharge piping, heaters supply separate DHW circuits, provide an individual circulator for each of the water heaters is approxi-
installed per GWC Boiler Manual each water heater, and control each circulator by its water heater’s aquastat. mately equal.
Part number 550-142-056/0411 27


Figure 35 Piping layout — typical for multiple GWC boilers, using isolation exchanger
Use isolation heat
exchanger for:
1. Large volume systems with high
mineral content in water.
2. Systems exposed to untreated
quantities of makeup water.
3. Old systems severely contami-
nated with scale and rust buildup
inside piping and heat distribu-
tion units.
4. Process applications.
5. Commercial service water ap-
plications.
6. High water pressure applications,
requiring pressure relief setting
in heating system more than 50
PSIG (tall buildings). See notes
below.
1 Flow/check valve (each boiler) 9 System automatic air vent Notes:
2 Isolation valves (when used) 1. Contact heat exchanger manufacturer for heat ex-
13 Cold water supply connections
changer shell-side and tube-side piping and circulator
3 Cap
16 Cold water fill line — see Fig- requirements. Tube-side flow and temperatures must
4 Secondary header (supply) — layout ure 32, page 25 for typical compo- meet heating system requirements.
and size per page 24 nents 2. Contact heat exchanger manufacturer for sizing heat
5 Secondary header (return) — layout exchanger.
18 Heating system supply
and size per page 24 3. Heat exchanger shell-side circuit requires its own
6a Heating system circulator (exchang- 19 Heating system return expansion tank as shown.
er tube-side) 4. Heating system circuit requires its own expansion tank,
20 Boiler relief valve and discharge pip-
as shown, plus its own relief valve set to protect heating
6b Heat exchanger shell-side circulator ing, installed per GWC Boiler Manual
system and heat exchanger piping and components.
7 Expansion tanks (diaphragm type) 30 Sensor for BCP (boiler control 5. When individual isolation valves are used, individual
8 System air eliminator panel), when used boiler and level controls may be required.
28 Part number 550-142-056/0411

Venting & air — general

GWC boilers must be vented and When removing a boiler from an existing
supplied with combustion and ven- common vent system
tilation air using piping and methods
described in this manual. The GWC boiler cannot be common vented with any other ap-
Every boiler must have its own vent. pliance. When an existing boiler is replaced with a GWC boiler, the GWC
DO NOT common vent with any other boiler CANNOT use the existing common vent. The GWC boiler requires
appliance. its own vent and air piping, as specified in this manual. This may cause a
Inspect finished vent and air piping problem for the appliances that remain on the old common vent, because
thoroughly to ensure all are airtight the vent may be too large. The following test, required by ANSI Z21.13,
and comply with the instructions is intended to check for proper operation of the appliances remaining on
provided and with all requirements of the old common vent system.
applicable codes.
Failure to provide a properly-installed Vent system verification
vent and air system will cause severe
personal injury or death. At the time of removal of an existing boiler, the following steps shall be
If the vent/air piping configurations followed with each appliance remaining connected to the common venting
covered in the GWC boiler manual system placed in operation, while the other appliances remaining connected
cannot be applied for a particular to the common venting system are not in operation. Seal any unused open-
installation, contact Williamson- ings in the common venting system.
Thermoflo for assistance. Other con-
figurations may be available.
Where vent piping is routed through
Existing vent test procedure
an unheated space, apply minimum
1 inch of foil-faced fiberglass insulation (The following is intended to test whether the appliances
on the length of the vent pipe in the remaining on an existing vent system will operate
unheated space. satisfactorily.)
Installations must comply with local 1. Visually inspect the venting system for proper size and horizontal pitch
requirements and with the National and determine there is no blockage or restriction, leakage, corrosion or
Fuel Gas Code, ANSI Z223.1 for U.S.
other deficiencies which could cause an unsafe condition.
installations or CSA B149.1 or B149.2
for Canadian installations. 2. Test vent system — Insofar as is practical, close all building doors and
Use only the materials listed in this windows and all doors between the space in which the appliances
manual for vent and air pipe and fit- remaining connected to the common venting system are located and
tings. See Figure 40, page 33. other spaces of the building. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn on any exhaust
If used, a masonry chimney can fans, such as range hoods and bathroom exhausts, so they will oper-
ONLY be used as a PIPE CHASE for
vent and air pipes — The vent and air ate at maximum speed. Do not operate a summer exhaust fan. Close
piping must be installed as instructed fireplace dampers.
in this manual and all joints must be
3. Place in operation the appliance being inspected. Follow the lighting in-
sealed. The chimney must be used only
for GWC boilers. NO OTHER appli- structions. Adjust thermostat so appliance will operate continuously.
ance or fireplace can be connected to 4. Test for spillage at draft hood relief opening after 5 minutes of main
the chimney. The chimney must be
burner operation. Use the flame of a match or candle, or smoke from
straight, with no offsets, and the vent
and air piping materials must comply a cigarette, cigar, or pipe.
with this instruction manual. The 5. After it has been determined that each appliance remaining connected
chimney must be fitted with a sealed to the common venting system properly vents when tested as outlined
access opening, through which the in-
terior of the chimney can be inspected. herein, return doors, windows, exhaust fans, fireplace dampers, and any
The chimney (and liner, if installed) other gas-burning appliance to their previous conditions of use.
must be inspected at least once annu-
ally to verify condition. Any improper operation of common venting system should be corrected
so the installation conforms with the National Fuel Gas Code, ANSI Z223.1
Failure to comply could result in severe — latest edition. Correct by re-sizing to approach the minimum size as
personal injury, death or substantial determined using the appropriate tables in Part 11 of that code. Canadian
property damage. installations must comply with B149.1 or B149.2 Installation Code.
Part number 550-142-056/0411 29

Venting & air — general (continued)

Provide combustion air: Combustion air contamination:
DIRECT VENT — The installation must provide com- Ensure that the combustion air will
bustion air piping. In addition, ventilation openings not contain any of the contaminants
may be required. in Figure 36.
DO NOT place combustion air supply
DIRECT EXHAUST — The installation must provide openings or intake terminations near
combustion air openings to the boiler space. a swimming pool, for example.
Avoid areas subject to exhaust fumes
ALL APPLICATIONS — The installation must provide from laundry facilities. These areas will
combustion air openings as needed for other appli- always contain contaminants.
ances in the space.
Figure 36 Corrosive contaminants and sources
Products to avoid
Vent and air termination options
Spray cans containing chloro/fluorocarbons
1. Vent and air piping must terminate out the sidewall or through the
roof of the building, using only one of the methods described in this Permanent wave solutions
manual. See Figure 39, page 32 and Figure 40, page 33 for allowable Chlorinated waxes/cleaners
configurations and piping materials.
Chlorine-based swimming pool chemicals
DIRECT VENT installations Calcium chloride used for thawing
1. For direct venting, combustion air must be piped from outside to the Sodium chloride used for water softening
boiler, following the instructions in this manual, and compliant with
all applicable codes. Refrigerant leaks
2. Ventilation openings are required for some spaces. See Fig- Paint or varnish removers
ure 42, page 36.
3. If other appliances are located in the same space with the GWC boiler, Hydrochloric acid/muriatic acid
provide openings shown in Figure 42, page 36. Cements and glues
If combustion and ventilation air openings are not provided
Antistatic fabric softeners used in clothes dryers
as directed above and the room does not have adequate
ventilation, the higher temperature in the space may result Chlorine-type bleaches, detergents, and cleaning
in reduced component life. solvents found in household laundry rooms
Adhesives used to fasten building products and
DIRECT EXHAUST installations other similar products
1. Combustion and ventilation air must be provided in the boiler room Excessive dust and dirt
on direct exhaust installations. Follow all instructions in this manual
(see page 47 for air opening instructions) and all applicable codes to Areas likely to have contaminants
provide required air openings. Dry cleaning/laundry areas and establishments
DO NOT sidewall vent DIRECT EXHAUST APPLICATIONS
Swimming pools
at altitudes above 5,500 feet. Sidewall venting is only allowed
for DIRECT VENT applications (ducted combustion air) at Metal fabrication plants
altitudes above 5,500 feet.
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
30 Part number 550-142-056/0411

Venting & air — general (continued)

Manifolded combustion air Figure 37 Combustion air manifold option (combined air inlet, but
option for DIRECT VENT individual vents) — must comply with Figure 41, page 35
multiple boiler installations
1. Multiple GWC boilers can use a common combus-
tion air manifold.
a. The combustion air inlet must be located in a
sidewall (and the vents must terminate on the
same side of the building).
b. See below for minimum cross sectional area of
combined air ducts.
c. Provide minimum clearance to adjacent vents
and grade/snow line as shown in Figure 37.
d. Provide minimum free area in duct (adjusted
for louver restriction) of 1 square inch per
2,000 Btuh total boiler input.
e. If combustion air damper is used, wire to boil-
ers to prevent operation except after damper
has opened.
ONLY air piping can be combined. DO
NOT use combined vent piping. All Figure 38 Maintain clearances and placement between the air
vent pipes must be routed and ter- manifold inlet and any appliance vent as shown below
minated individually as described in
this manual. Flue gas leakage and boiler
component damage can occur. Failure to
comply could result in severe personal
injury, death or substantial property
damage.
Air manifold sizing

1. See Figure 106, page 100 for minimum cross sec-
tional area of combined air ducts.
OR
2. Calculate required cross section (for area in
square inches):
a. MIN. AREA = TOTAL MBH INPUT DIVIDED
BY 2
3. Example:
a. A multiple boiler system with (4) GWC-140
boilers has a total input of 4 x 140 = 560 MBH
(560,000 Btuh).
b. The required duct cross sectional area is:
c. MIN. AREA = 560 DIVIDED BY 2
= 280 sq. inches
The air manifold inlet of GWC boilers is part of direct vent connections. It is not classified as a forced air intake
with regard to spacing from adjacent boiler vents. To avoid recirculation, however, you must install the vent ter-
minations and air inlets with the clearances specified in Figure 38, page 31. The vent must be located following the
restrictions shown in Figure 41, page 35. The vent termination configuration can be any of the sidewall methods
(NOT VERTICAL) shown in this manual for direct vent or direct exhaust sidewall termination installations. THE
VENTS MUST BE TERMINATED THROUGH THE SAME SIDE WALL AS THE AIR MANIFOLD INLET.
Part number 550-142-056/0411 31

Venting & air — general (cont.)
Figure 39 GWC venting and air piping — OPTIONS and PIPING LIMITS
Vent length affects boiler input — the boiler automatically derates to compensate for pressure loss through the vent.
See the derate values given in Figure 105, page 99. The longer the vent, the more the input is reduced.
Maximum vent and air pipe lengths

(Minimum length for all applications is 2 feet)
(All applications include allowance for the termination fittings)
DIRECT VENT DIRECT EXHAUST

(combustion air piped to boiler from outside) (combustion air from inside)
SIDEWALL VERTICAL SIDEWALL VERTICAL

termination termination termination termination
GWC Model
3” PVC 3” PVC 3” PVC 3” PVC 3” PVC 3” PVC

Separate pipes Concentric Separate pipes Concentric Coupling Coupling
[Note 1] [Note 1] or Elbow
See page 37 See page 39 See page 41 See page 43 See page 49 See page 51
Max. Max. Max. Max. Max. Max.

Length Length Length Length Length Length
(feet) (feet) (feet) (feet) (feet) (feet)
-070 100 100 100 100 100 100
-105 100 100 100 100 100 100
-140 100 100 100 100 100 100
-175 100 100 100 100 100 100
Equivalent feet for elbows — deduct from maximum equivalent length of piping (does not apply to termination fittings)
• 7 feet per for each 3-inch 90° long-radius or 45° elbow
• 16 feet for each 3-inch short-radius elbow
Use only PVC pipe DO NOT use CPVC or ABS with concentric termination kits.
IPEX 3” PVC concentric vent kits can be used with standard PVC pipe, fittings and cement (ANSI/ASTM D1785) except where ULC
Note 1: S636 compliance is required. For ULC S636 compliance, all pipe, fittings and cement must be IPEX System 636. When using IPEX
kits, use only IPEX product code 196006 for 3” venting.
Contact Williamson-Thermoflo for ordering information and availability of Williamson-Thermoflo venting kits.
32 Part number 550-142-056/0411

Venting & air — general (cont.)

Figure 40 Vent and air piping materials — Use only the materials listed below, ensuring that all materials meet
local codes
Standards for installations in:

Item Material
United States Canada
Plastic piping materials
PVC schedule 40 ANSI/ASTM D1785
Vent or air pipe PVC-DWV (Note 1) ANSI/ASTM D2665

&
fittings CPVC schedule 40 (Note 1) ANSI/ASTM F441 Plastic vent pipe must be certified to
ULC S636 when required. (Note 2)
ABS-DWV schedule 40 (Note 1) ANSI/ASTM D2661
Air pipe can be any of those listed at
PVC ANSI/ASTM D2564 left if acceptable for local codes.
PVC & ABS pipe

CPVC (Note 1) ANSI/ASTM F493
cement & primer
ABS (Note 1) ANSI/ASTM D2235
AL29-4C piping materials

Heat Fab, Inc. — Saf-T-Vent®
Vent pipe
AL29-4C Z-Flex, Inc. — Z-Vent II Certified for Category IV and direct vent
—
stainless Dura-Vent — FasNSeal™ appliance venting
steel
Metal-Fab, Inc. — CORR/GUARD
Williamson-Thermoflo bird screens (included with boiler)

Williamson- 3” bird screen:
Thermoflo W-T part number 383-500-105WT
bird screens (two supplied with the boiler)
Note 1: DO NOT use DWV, CPVC or ABS when using concentric vent termination. Use ONLY PVC schedule 40.
Note 2: IPEX PVC concentric terminations utilize PVC pipe/fittings certified to ULC S636. Where ULC S636 compliance is required, use
only IPEX System 636 pipe, fittings and cement.
AL29-4C vent piping — Install a PVC-to-stainless adapter supplied by the vent pipe manufacturer at the boiler vent connection
and at the termination (when using concentric PVC termination). DO NOT mix piping from different vent pipe manufacturers
unless using adapters specifically designed for the purpose by the manufacturer.
Plastic piping — Do not attempt to connect different types of plastic piping together.
DO NOT use cellular core pipe.
All vent and air pipes require a bird screen at each termination. Two bird
screens are supplied with each GWC boiler.
Part number 550-142-056/0411 33

Commonwealth of Massachusetts installations
Commonwealth of Massachusetts — When the boiler is installed within the Commonwealth of Massachusetts,
the boiler must be installed by a licensed plumber or gas fitter. Read and comply with the instructions below.
(a) For all sidewall horizontally-vented gas-fueled equipment 4. INSPECTION. The state or local gas inspector of the
installed in every dwelling, building or structure used in side wall horizontally vented gas fueled equipment shall
whole or in part for residential purposes, including those not approve the installation unless, upon inspection,
owned or operated by the Commonwealth and where the the inspector observes carbon monoxide detectors and
side wall exhaust vent termination is less than seven (7) feet signage installed in accordance with the provisions of
above finished grade in the area of the venting, including but 248 CMR 5.08(2)(a) 1 through 4.
not limited to decks and porches, the following requirements
shall be satisfied: (b) EXEMPTIONS: The following equipment is exempt from
248 CMR 5.08(2)(a)1 through 4:
1. INSTALLATION OF CARBON MONOXIDE DETEC-
TORS. At the time of installation of the side wall horizon- 1. The equipment listed in Chapter 10 entitled “Equipment
tal vented gas fueled equipment, the installing plumber Not Required To Be Vented” in the most current edition
or gas fitter shall observe that a hard wired carbon of NFPA 54 as adopted by the Board; and
monoxide detector with an alarm and battery back-up 2. Product Approved side wall horizontally vented gas fueled
is installed on the floor level where the gas equipment is equipment installed in a room or structure separate from
to be installed. In addition, the installing plumber or gas the dwelling, building or structure used in whole or in
fitter shall observe that a battery operated or hard wired part for residential purposes.
carbon monoxide detector with an alarm is installed on
each additional level of the dwelling, building or struc- (c) MANUFACTURER REQUIREMENTS — GAS EQUIPMENT
ture served by the side wall horizontal vented gas fueled VENTING SYSTEM PROVIDED. When the manufacturer of
equipment. It shall be the responsibility of the property Product Approved side wall horizontally vented gas equip-
owner to secure the services of qualified licensed profes- ment provides a venting system design or venting system
sionals for the installation of hard wired carbon monoxide components with the equipment, the instructions provided
detectors by the manufacturer for installation of the equipment and
a. In the event that the side wall horizontally vented gas the venting system shall include:
fueled equipment is installed in a crawl space or an 1. Detailed instructions for the installation of the venting
attic, the hard wired carbon monoxide detector with system design or the venting system components; and
alarm and battery back-up may be installed on the 2. A complete parts list for the venting system design or
next adjacent floor level. venting system.
b. In the event that the requirements of this subdivision
can not be met at the time of completion of installa- (d) MANUFACTURER REQUIREMENTS — GAS EQUIPMENT
tion, the owner shall have a period of thirty (30) days VENTING SYSTEM NOT PROVIDED. When the manufac-
to comply with the above requirements; provided, turer of a Product Approved side wall horizontally vented gas
however, that during said thirty (30) day period, a
fueled equipment does not provide the parts for venting the
battery operated carbon monoxide detector with an
flue gases, but identifies “special venting systems”, the follow-
alarm shall be installed.
ing requirements shall be satisfied by the manufacturer:
2. APPROVED CARBON MONOXIDE DETECTORS. Each 1. The referenced “special venting system” instructions shall
carbon monoxide detector as required in accordance with be included with the appliance or equipment installation
the above provisions shall comply with NFPA 720 and be instructions; and
ANSI/UL 2034 listed and IAS certified. 2. The “special venting systems” shall be Product Approved
3. SIGNAGE. A metal or plastic identification plate shall by the Board, and the instructions for that system shall in-
be permanently mounted to the exterior of the build- clude a parts list and detailed installation instructions.
ing at a minimum height of eight (8) feet above grade
directly in line with the exhaust vent terminal for the (e) A copy of all installation instructions for all Product Approved
horizontally vented gas fueled heating appliance or side wall horizontally vented gas fueled equipment, all venting
equipment. The sign shall read, in print size no less than instructions, all parts lists for venting instructions, and/or all
one-half (1/2) inch in size, “GAS VENT DIRECTLY BE- venting design instructions shall remain with the appliance
LOW. KEEP CLEAR OF ALL OBSTRUCTIONS.” or equipment at the completion of the installation.
34 Part number 550-142-056/0411

Vent termination requirements

Figure 41 The vent termination must be located to meet all requirements below (also applies to vertical vent terminations).
For Canadian installations, defer to the requirements of CSA B149.1 or B149.2 Installation Code.
Part number 550-142-056/0411 35

DIRECT VENT — Boiler room air openings

Figure 42 Combustion and ventilation air openings for GWC Direct Vent installations
The GWC boiler CANNOT be in the same space with other appliances if clearances around the GWC are less than
the recommended service clearances shown in Figure 2, page 6.
Air openings GWC boiler GWC boiler

The required air opening sizes below are FREE AREA, WITH other WITHOUT other
after reduction for louver obstruction. Note the ex-
ception below for large spaces. appliances in room appliances in room
TWO openings, each at least:

1 square inch per 1,000 Btuh
of all other appliances in the room

— OR —
ONE opening **, each at least: NO openings are required if the
1 square inch per 3,000 Btuh boiler installation provides at least the
of all other appliances in the room recommended service clearances
shown in Figure 2, page 6.
TWO openings, each at least: If the space is smaller than Fig-

1 square inch per 2,000 Btuh ure 2, page 6, provide openings
of all other appliances in the room ONLY as shown on page 7 and
— OR — Figure 4, page 7.
ONE opening **, each at least:

— OR —
ONE opening **, each at least:
A single combustion air opening can be used for cases b, c or d above (GWC with
other appliances in room only), sized as listed, provided that:
** NOTICE: • The single opening must communicate directly to the outdoors or to a space that
Requirements for using the SINGLE air opening communicates directly with outdoors (NOT to an interior space).
option. • The top of the opening must be within 12 inches of the ceiling.
• The free area of the opening must be at least equal to the sum of the areas of all
equipment vent connectors in the space.
NO combustion air openings are needed when the boiler (and other appliances) are
installed in a space with a volume NO LESS than 50 cubic feet per 1,000 Btuh of all ap-
SPECIAL EXCEPTION FOR LARGE SPACES pliances in the space. That is, total the input of all appliances in MBH (1,000’s of Btuh),
then multiply this total times 50. The building MUST NOT be of tight construction.
(GWC WITH other appliances in room only):
Example: For a total input of 500 MBH (500,000 Btuh), the minimum volume would be
50 x 500 = 25,000 cubic feet (3,125 square feet if ceiling height is 8 feet).
36 Part number 550-142-056/0411

DIRECT VENT — Sidewall with separate pipes

Allowable vent/air pipe materials & Figure 43 Installation sequence — Separate pipes sidewall
lengths
Use only the vent materials and kits
listed in Figure 40, page 33. Provide
pipe adapters if specified.
1. Locate the termination such that the total air
piping and vent piping from the boiler to the
termination will not exceed the maximum
length given in Figure 39, page 32.
Determine termination location

1. The air and vent terminations must be in-
stalled as shown in Figure 43, page 37 and
Figure 45, page 38.
2. The terminations must comply with clearances
and limitations shown in Figure 41, page 35.
3. Locate the terminations so they are not likely
to be damaged by foreign objects, such as
stones or balls, or subject to buildup of leaves
or sediment.
Step 1 Read and follow all instructions in this manual. DO NOT proceed with
Do not exceed the maximum lengths vent/air installation until you have read page 29 through page 35.
of the outside vent piping shown in
Figure 43, page 37. Excessive length Step 2 Install the boiler in a location that allows proper routing of all vent and air
exposed to the outside could cause piping to the selected sidewall location.
freezing of condensate in the vent Step 3 Make sure the selected sidewall termination location complies with Fig-
pipe, resulting in potential boiler ure 41, page 35. (Multiple boiler sidewall plates must also comply with
shutdown. In extremely cold cli- Figure 44, page 38.)
mates, install an insulated chase
around the vent piping, particu- Step 4 Use only the vent materials listed in Figure 40, page 33. Provide pipe adapt-
larly when using longer lengths. The ers where required. Vent piping and air piping lengths must not exceed the
chase must allow for inspection of values shown in Figure 39, page 32. In addition to the vent materials,
this installation requires two (2) W-T sidewall termination plates and
the vent pipe, and insulation must
a bird screen for air and vent termination fittings, unless using an
be protected from water. AL29-4C vent termination fitting with integral screen. Two plates and
two bird screens are supplied with the boiler for use with 3" PVC piping.
Multiple vent/air terminations
Step 5 Prepare the sidewall penetrations and secure the sidewall plates as instructed
1. When terminating multiple GWC boilers, ter- in this section. See “Prepare wall penetrations” on page 38.
minate each vent/air connection as described
Step 6 The air piping must terminate in a down-turned elbow as shown above.
in this manual.
The vent piping must terminate in an elbow pointed outward or away
All vent pipes and air inlets must from the air inlet as shown above. See illustration above.
terminate at the same height to Step 7 Install vent and air piping between the boiler and the sidewall openings.
avoid possibility of severe personal Slope horizontal piping downward toward the boiler at least 1/4 inch per
injury, death or substantial property foot. See page 46 for general guidelines.
damage.
Step 8 Install pipe supports every 5 feet on both the horizontal and vertical runs.
2. Place wall penetrations to obtain minimum Install a hanger support within 6 inches of any upturn in the piping.
clearances shown in Figure 44, page 38 for Step 9 Attach the vent termination exterior piping: Use either of the configura-
U. S. installations. For Canadian installations, tions shown above, as needed to ensure clearance above grade or snow line.
provide clearances required by CSA B149.1 or
B149.2 Installation Code. Step 10 The vent and air pipes may run up as high as 4 feet with no enclosure.
The vent and air pipes must be secured with braces, and all clearances and
3. The air inlet of a GWC boiler is part of a direct lengths must be maintained. Space braces no further than 24 inches apart.
vent connection. It is not classified as a forced
air intake with regard to spacing from adjacent Step 11 External venting greater than 4 feet requires an insulated enclosure around
boiler vents. the vent and air pipes. The vent and air terminations must exit through
the enclosure as shown in the illustration above, maintaining all required
4. Combustion air (NOT vent piping) can be clearances.
manifolded as shown in Figure 37, page 31.
Part number 550-142-056/0411 37

DIRECT VENT — Sidewall with separate pipes (continued)

For multiple boiler applications using the manifolded Figure 44 Multiple separate pipes sidewall terminations
combustion air option, the vent can be terminated in
an elbow as in Figure 43, page 37, or in a coupling or
sidewall termination plate. The vents must be located
following the restrictions in Figure 41, page 35 and
Figure 38, page 31.
In addition to the vent materials, this installation requires

two (2) W-T sidewall termination plates and a bird screen
for each air and vent termination fitting, unless using an
AL29-4C vent termination fitting with integral screen. Two
plates and two bird screens are supplied with the boiler.
Prepare wall penetrations

1. Two W-T sidewall termination plates are included with each boiler.
Use one of the sidewall termination plates as a template to mark
air pipe and vent pipe hole locations.
a. Hole centers in the plates are 3¾" apart.
b. Hole diameters are 3.14" for holes as is. Use as is for 3" AL29-4C
pipe. Remove knockout to provide 35⁄8" hole for 3" PVC pipe.
2. Air pipe penetration:
a. Cut a hole for the air pipe.
b. Size the air pipe hole as close as desired to the air pipe outside
diameter.
3. Vent pipe penetration:
a. Cut a hole for the vent pipe.
b. Cut the vent pipe hole to at least 3.9 inches for 3" PVC vent or
3.4" for 3" AL29-4C vent.
c. Insert a galvanized metal thimble in the vent pipe hole as
shown in Figure 45.
4. Follow all local codes for isolation of vent pipe when passing
through floors or walls. Figure 45 Sidewall termination assembly — using
5. Seal exterior openings thoroughly with exterior caulk. separate pipes
Termination and fittings

1. Prepare the vent termination elbow and the air termination elbow
by inserting bird screens, unless using an AL29-4C vent termina-
tion fitting with integral screen. (See Figure 43, page 37.) Two bird
screens are supplied with the boiler.
2. When completed, the air termination elbow opening must be
oriented at least 12 inches below the vent termination and at least
12 inches above grade or snow line as shown in Figure 43, page 37.
3. You can orient the vent termination elbow either directly out-
ward or 90 degrees away from the air inlet elbow as shown in
Figure 43, page 37.
4. Maintain the required dimensions of the finished termination
piping as shown in Figure 43, page 37.
5. For multiple boiler terminations, see Figure 44, page 38.
6. Do not extend exposed vent pipe outside of building more than 1 Vent piping 5 Bird screens, supplied with
shown in this document. Condensate could freeze and block vent 2 Air piping boiler
pipe. 3 W-T sidewall termination plates, supplied 6 Air inlet elbow
with boiler (remove knockout if using PVC
7 Elbow
If extending the vent and air pipes out from the wall, pipe; leave knockout in if using AL29-4C
vent pipe) 8 Nipple
install a coupling on each pipe. Mount the piping with 4 Galvanized thimbles, by installer 9 Elbow (vent termination)
the coupling flush with the outer plate.
38 Part number 550-142-056/0411

DIRECT VENT — Sidewall with 3” concentric

Allowable vent/air pipe materials & Figure 46 Installation sequence — Concentric horizontal
lengths
1. The 3” concentric termination kit must be pur-
chased separately.
Use only the vent materials and kits listed
in Figure 40, page 33. Provide pipe adapt-
ers if specified.
2. Locate the termination such that the total air piping
and vent piping from the boiler to the termina-
tion will not exceed the maximum length given in
Figure 39, page 32.
3. This termination requires a 45-degree elbow that
is not supplied with the termination kit. The
maximum vent/air pipe lengths include allowance
for this elbow.

1. The concentric termination kit must be installed
as shown in Figure 46, page 39.
2. The termination must comply with clearances and
limitations shown in Figure 41, page 35.
3. Locate the termination so it is not likely to be dam-
aged by foreign objects, such as stones or balls, or
subject to buildup of leaves or sediment.

1. When terminating multiple GWC boilers, install Step 1 Read and follow all instructions in this manual. DO NOT
each concentric termination as described in this proceed with vent/air installation until you have read
manual. page 29 through page 35.
All vent pipes and air inlets must ter- Step 2 Install the boiler in a location that allows proper routing of
minate at the same height to avoid pos- all vent and air piping to the selected sidewall location.
sibility of severe personal injury, death or
Step 3 Make sure the selected sidewall termination location com-
plies with Figure 41, page 35. (Multiple boiler concentric
2. Place wall penetrations to obtain minimum terminations must also comply with Figure 47, page 40.)
clearance as shown in Figure 47, page 40 for U. S.
installations. For Canadian installations, provide Step 4 Use only the vent materials listed in Figure 40, page 33.
clearances required by CSA B149.1 or B149.2 In- Provide pipe adapters where required.
stallation Code. Step 5 Vent piping and air piping lengths must not exceed the
3. The air inlet of a GWC boiler is part of a direct vent values shown in Figure 39, page 32.
connection. It is not classified as a forced air intake
Step 6 The concentric termination must be assembled and installed
with regard to spacing from adjacent boiler vents.
before piping from the boiler to the termination.
Step 7 Prepare the sidewall penetration — assemble the concentric
termination kit and secure the cover plates as instructed in
this section. Provide the supports indicated and mount the
termination assembly. See “Install termination — concentric
pipes” on page 40.
Step 8 Install vent and air piping between the boiler and the
concentric vent/air termination. Slope horizontal piping
downward toward the boiler at least 1/4 inch per foot. See
page 46 for general guidelines.
Step 9 Install pipe supports every 5 feet on both the horizontal and
vertical runs.
Step 10 Install a hanger support within 6 inches of any upturn in
the piping.
Part number 550-142-056/0411 39

DIRECT VENT — Sidewall with 3” concentric (continued)

Install termination — concentric pipes Figure 47 Termination location — concentric
1. Assemble the vent termination as described for concentric termi- termination — multiple boilers —
nations, on page 45. clearance from vent of one to air intake of
the next
If necessary, you can shorten the lengths of the inner and
outer pipes for a shorter finished assembly. But you must
ensure the pipes butt correctly at both ends. Failure to
properly assemble the concentric termination can result
in flue gas recirculation, causing possible severe personal
injury or death.
2. Wall penetration:
a. Preferably, use a thimble with a 4½-inch hole. If not using a
thimble, carefully use a hole saw to cut a hole not larger than
4¾ inches in diameter through the wall. The finished hole
must provide a solid stop for the rain cap ribs, as shown in the
inset to Figure 48.
3. Secure the termination in place so the rain cap will butt against the
outside wall or outer thimble plate as shown in Figure 48, page 40.
4. Before beginning vent and air piping from the boiler to the con-
centric termination, mount and secure the concentric termination
as shown in Figure 48, page 40. Figure 48 Installing and supporting the concentric
The vent and air piping must be securely supported, and sidewall vent assembly
must not rest its weight on the boiler fittings. Failure to
properly support the vent and air piping could result in
vent piping damage, resulting in possible severe personal
injury, death or substantial property damage.
The supports/bracing used must support the termination
assembly to prevent slippage or movement.
The clamps used on the outside of the termination pipe
must not cut into the pipe or contain sharp edges that
could cause a crack to form.
When inserting the partially-assembled termination
kit through the wall penetration, wrap plastic or other
protection over the end of the exposed assembly to pre-
vent debris from entering the pipes. If the air passages
become blocked, the boiler will not operate. Once the
rain cap has been cemented to the assembly, there is no
way to correct the problem. The assembly would have
to be replaced if it were cut to be removed and cleaned.
Altering the assembly in any way could result in severe
personal injury or death due to toxic flue product emis-
sions.
When using AL294C stainless vent pipe, use the vent
pipe manufacturer’s PVC adapter when connecting to
the concentric vent attachment.
5. After the assembly has been positioned in the opening and all Ensure that the wall material is strong
supports have been attached, install a bird screen (supplied with
boiler) and rain cap as follows: enough to prevent the rain cap from being
a. Place the bird screen on the end of the inner pipe as in Fig- pushed inward if struck or pushed from the
ure 54, page 45. outside.
b. Cement the rain cap in place as shown.
40 Part number 550-142-056/0411

DIRECT VENT — Vertical with separate pipes

Allowable vent/air pipe materials & Figure 49 Separate pipes vertical termination
lengths
ers if specified.
1. Locate the terminations such that the total air pip-
ing and vent piping from the boiler to the termina-
Figure 39, page 32.

1. The air and vent terminations must be installed as
2. The terminations must comply with clearances and
3. Locate the terminations so they are not likely to be
damaged by foreign objects, such as stones or balls,
or subject to buildup of leaves or sediment.
Multiple vent/air terminations (Figure 50)

1. When terminating multiple GWC boilers, termi-
nate each vent/air connection as described in this
section.
Step 1 Read and follow all instructions in this manual. DO NOT proceed
Terminate all vent pipes at the same with vent/air installation until you have read page 29
through page 35.
height and all air pipes at the same height
to avoid possibility of severe personal Step 2 Install the boiler in a location that allows proper routing of all vent
injury, death or substantial property and air piping to the selected sidewall location.
damage.
Step 3 Make sure the selected vertical termination location complies with
2. Place roof penetrations to obtain minimum clear- Figure 41, page 35. (Multiple boiler terminations must also comply
ance of 12 inches between edge of air intake elbow with Figure 50, page 42.)
and adjacent vent pipe of another boiler for U. S. Step 4 Use only the vent materials listed in Figure 40, page 33. Provide pipe
installations (see Figure 50, page 42). For Canadian adapters where required. Vent piping and air piping lengths must not
installations, provide clearances required by CSA exceed the values shown in Figure 39, page 32.
B149.1 or B149.2 Installation Code.
Step 5 Prepare the vertical penetrations and secure penetration components
3. The air inlet of a GWC boiler is part of a direct vent as instructed in this section. See “Prepare roof penetrations” on page 41
connection. It is not classified as a forced air intake and “Termination and fittings” on page 42.
with regard to spacing from adjacent boiler vents. Step 6 The air piping must terminate in a 180-degree return bend or down-
turned elbow as shown above. The vent piping must terminate in a
Prepare roof penetrations coupling pointed upward as shown above. Vent and air termina-
tions must be fitted with bird screens as shown. Two bird screens are
1. Air pipe penetration: supplied with the boiler.
a. Cut a hole for the air pipe. Size the air pipe Step 7 Install vent and air piping between the boiler and the vertical termina-
hole as close as desired to the air pipe outside tions. Slope horizontal piping downward toward the boiler at least 1/4
diameter. inch per foot. Install pipe supports every 5 feet on both the horizontal
and vertical runs. Install a hanger support within 6 inches of any upturn
2. Vent pipe penetration: in the piping. See page 46 for general guidelines.
a. Cut a hole for the vent pipe. For either combus- Step 8 Insert the vent and air piping through the vertical penetrations and
tible or noncombustible construction, size the secure the termination fittings.
vent pipe hole at least 0.4” larger than the vent
pipe diameter (4” hole for 3” PVC). Step 9 Maintain clearances shown above. Vent and air terminations must
be fitted with a bird screen as shown. See Figure 92, page 87 for part
b. Insert a galvanized metal thimble in the vent numbers.
pipe hole.
Part number 550-142-056/0411 41

DIRECT VENT — Vertical with separate pipes (continued)

3. Space the air and vent holes to provide the minimum spacings
Figure 50 Terminations for multiple boilers
through floors, ceilings and roofs.
5. Provide flashing and sealing boots sized for the vent pipe and air
pipe.

1. Prepare the vent termination elbow and the air termination elbow
(Figure 49, page 41) by inserting bird screens. Two bird screens are
supplied with the boiler.
2. The air piping must terminate in a down-turned 180-degree re-

turn bend as shown in Figure 49, page 41. Locate the air inlet pipe
no further than 12 inches from the center of the vent pipe. This
placement avoids recirculation of flue products into the combus-
tion air stream.
3. The vent piping must terminate in an up-turned coupling as shown

in Figure 49, page 41. The top of the coupling must be at least 1 foot
above the air intake. The air inlet pipe and vent pipe can be located
in any desired position on the roof, but must always be no further
than 12 inches apart and with the vent termination at least 1 foot
above the air intake.

5. Do not extend exposed vent pipe outside of building more than Also maintain maximum center-to-center
shown in this document. Condensate could freeze and block vent distances between the vent and air pipes for
pipe. each boiler as shown in Figure 49, page 41.
42 Part number 550-142-056/0411

DIRECT VENT — Vertical with 3” concentric

Allowable vent/air pipe materials & Figure 51 Installation sequence — Concentric vertical
lengths
1. The 3” concentric termination kit must be pur-
chased separately.
ers if specified.
Figure 39, page 32.
3. This termination requires a 45-degree elbow that
is not supplied with the termination kit. The
maximum vent/air pipe lengths include allowance
for this elbow.

Locate the concentric vent/air termination using the
following guidelines:
1. The concentric vent/air assembly must terminate
as shown in Figure 52, page 44.
2. The termination must comply with the clearances
and limitations shown in Figure 41, page 35.
subject to buildup of leaves or sediment. Step 1 Read and follow all instructions in this manual. DO NOT
4. For Canadian installations, follow requirements of proceed with vent/air installation until you have read
CSA B149.1 or B149.2 Installation Code. page 29 through page 35.
Step 2 Install the boiler in a location that allows proper routing of
Multiple vent/air terminations all vent and air piping to the selected sidewall location.
1. When terminating multiple GWC boilers, install
Step 3 Make sure the selected vertical termination location com-
the concentric vent/air termination assemblies as plies with Figure 41, page 35. (Multiple boiler concentric
described in this manual. terminations must also comply with Figure 52, page 44.)
All vent outlets must terminate at the Step 4 Use only the vent materials listed in Figure 40, page 33.
same height to avoid possibility of severe Provide pipe adapters where required.
personal injury, death or substantial
property damage. Step 5 Vent piping and air piping lengths must not exceed the
values shown in Figure 39, page 32.
2. Place roof penetrations to obtain minimum of
12 inches between centers of adjacent vent pipe Step 6 The concentric termination must be assembled and installed
of another boiler for U. S. installations (see Fig- before piping from the boiler to the termination.
ure 52, page 44). Step 7 Prepare the vertical penetration(s) — assemble the concen-
3. The air inlet of a GWC boiler is part of a direct vent tric termination kit and secure the penetration components
connection. It is not classified as a forced air intake as instructed in this section. Provide the supports indicated
with regard to spacing from adjacent boiler vents. and mount the termination assembly. See “Prepare roof
penetrations” on page 43 and “Mount concentric termina-
Prepare roof penetrations tion” on page 44.
1. Roof penetration hole: Step 8 Install vent and air piping between the boiler and the
a. Cut a 5-inch diameter hole to clear the 4½-inch concentric vent/air termination. Slope horizontal piping
termination outside diameter. downward toward the boiler at least 1/4 inch per foot. See
b. Insert a galvanized metal thimble in the vent page 46 for general guidelines.
pipe hole. Step 9 Install pipe supports every 5 feet on both the horizontal and
2. Follow all local codes for isolation of vent pipe when vertical runs.
passing through floors, ceilings and roofs. Step 10 Install a hanger support within 6 inches of any upturn in
3. Provide flashing and sealing boots sized for the the piping.
concentric termination outside diameter.
Part number 550-142-056/0411 43

DIRECT VENT — Vertical with 3” concentric (continued)

Mount concentric termination Figure 52 Vertical termination — 3” PVC concentric
1. Mount the termination as shown in Figure 53, page 44. — single or multiple boilers
2. Support the concentric vent/air termination at the roof penetration
as shown in Figure 53.
• The supports/bracing used must support the termination as-
sembly to prevent vertical slippage or sideways movement.
• The clamps used on the outside of the termination pipe must
not cut into the pipe or contain sharp edges that could cause
a crack to form.
The vent and air piping must be securely supported,
and must not rest its weight on the boiler fittings. DO
NOT drill or screw into either the vent pipe or air pipe.
Failure to properly support the vent and air piping could
result in vent piping damage, resulting in possible severe
When inserting the partially-assembled termination
kit through the roof penetration, wrap plastic or other
protection over the end of the exposed assembly to pre-
vent debris from entering the pipes. If the air passages
become blocked, the boiler will not operate. Once the
rain cap has been cemented to the assembly, there is no
way to correct the problem. The assembly would have
to be replaced if it were cut to be removed and cleaned.
Altering the assembly in any way could result in severe
personal injury or death due to toxic flue product emis- Figure 53 3” PVC concentric termination supports
sions.
When using AL294C stainless vent pipe, use the vent
pipe manufacturer’s PVC adapter when connecting to
the concentric vent attachment.
Do not connect any other appliance to the vent pipe or
multiple boilers to a common vent pipe.
3. After the assembly has been positioned in the roof opening and all
supports have been attached, install a bird screen (two bird screens
are supplied with the boiler) and rain cap as follows:
a. Place the bird screen on the end of the inner pipe as in Fig-
ure 54, page 45.
b. Cement the rain cap in place.
44 Part number 550-142-056/0411

Concentric termination assembly (sidewall or vertical)
Figure 54 3” PVC concentric termination assembly — DO NOT Assembling concentric termination

attach the rain cap until the termination has been 1. See Figure 54, page 45 for the details of the termi-
inserted through the roof or wall and all supports have
nation assembly.
been installed.
2. Prepare the bird screen (two bird screens are sup-
plied with the boiler). Cut the bird screen to size if
required. If the bird screen must be trimmed, cut
the bird screen to fit the outside diameter of the
PVC inner pipe supplied with the termination kit.
3. Partially assemble the vent termination kit in the
sequence shown in Figure 54, page 45.
DO NOT install the rain cap and bird

screen until the assembly has been in-
serted through the roof (or sidewall)
and all supports have been installed.
Follow instructions to cover the end of
the assembly with plastic before inserting
through the roof penetration to prevent
debris from blocking the air passages.
4. Use the following procedures to prepare termina-
tion components and cement together.
5. Deburr inside and outside of pipe ends.
6. Chamfer outside of each pipe end to ensure even
cement distribution when joining.
7. Clean all pipe ends and fittings.
8. Dry thoroughly.
9. Dry assemble entire vent or air piping to ensure
proper fit before assembling any joint.
10. For each joint:
a. Handle fittings and pipes carefully to prevent
contamination of surfaces.
b. Apply primer liberally to both joint surfaces —
pipe end and fitting socket.
c. While primer is still damp, lightly apply ap-
proved cement to both surfaces in a uniform
coating.
d. Apply a second coat to both surfaces. Avoid
using too much cement on sockets to prevent
cement buildup inside.
e. With cement still wet, insert pipe into fit-
ting, twisting ¼ turn. Make sure pipe is fully
inserted.
If necessary, you can shorten the lengths

of the inner and outer pipes for a shorter
finished assembly. But you must ensure
the pipes butt correctly at both ends. Fail-
ure to properly assemble the concentric
termination can result in flue gas recir-
culation, causing possible severe personal
injury or death.
Part number 550-142-056/0411 45

Vent and air piping and boiler connections

DIRECT EXHAUST & DIRECT VENT Figure 55 Boiler vent and air connections
Follow termination instructions

1. Read and follow all instructions for the termination
type used before proceeding with this page.
Installing vent and air piping

1. Work from the boiler to vent or air termination. Do
not exceed the lengths given in the previous pages
for either the air or vent piping.
a. Provide stainless pipe to PVC adapters obtained
from the stainless pipe manufacturer for con-
nections at the boiler and at terminations, when
required.
2. See Figure 55 for attaching vent (and air) pipes at
the boiler.
3. Cut pipe to required lengths.
4. Deburr inside and outside of pipe ends.
5. Chamfer outside of each pipe end to ensure even
cement distribution when joining.
6. Clean all pipe ends and fittings. Dry thoroughly. AL294C vent pipe — If using AL294C stainless vent pipe,
you must install an AL29-4C stainless vent starter at the
7. Dry assemble entire vent or air piping to ensure boiler vent connection (and at the termination if using
proper fit before assembling any joint. the PVC concentric termination). Use only the starter
made by the vent pipe manufacturer. See Replacement
8. For each joint: parts section for available AL29-4C stainless vent starters.
a. Handle fittings and pipes carefully to prevent 1. PVC/ABS pipe — Clean and deburr inside and outside of other
contamination of surfaces. both ends of air and vent pipes. Chamfer boiler end of vent pipe
b. Apply primer liberally to both joint surfaces — for ease of insertion.
pipe end and fitting socket. The vent pipe end must be smooth and chamfered to
c. While primer is still damp, lightly apply ap- prevent possible damage to sealing gasket in vent pipe
proved cement to both surfaces in a uniform adapter.
coating. 2. Inspect vent adapter and air inlet fitting (above) — verify no ob-
d. Apply a second coat to both surfaces. Avoid structions or foreign objects inside.
using too much cement on sockets to prevent 3. Vent pipe
cement buildup inside. • Loosen vent adapter clamp screw.
e. With cement still wet, insert pipe into fit- • Measure 3½ inches from boiler end of vent pipe and make a
ting, twisting ¼ turn. Make sure pipe is fully mark with felt-tip pen.
inserted. • Apply small amount of silicon grease to boiler end of vent pipe
f. Wipe excess cement from joint. Check joint to to ease insertion.
be sure a smooth bead of cement shows around • Insert vent pipe into adapter to depth of felt tip pen mark.
the entire joint. • Secure vent pipe by tightening the adapter clamp securely. Do
9. Maintain minimum clearance of C\zn inch between not overtighten. The seal is accomplished with the internal
vent pipe and any combustible wall or material. gasket. The clamp is only to hold the pipe in place.
Do not apply excessive force or bend the vent adapter
10. Seal wall or floor penetration openings following or vent pipe when inserting. The adapter or seal could
local code requirements. be damaged.
4. Air pipe
DIRECT EXHAUST ONLY • Clean the outer surface of the boiler end of the air pipe.
• Apply silicon sealant (Dow Corning 732TM or equivalent) to
DIRECT EXHAUST installations — air the outside end of the air pipe and to the inside of the air inlet
inlet opening protection: Insert one of fitting.
the bird screens supplied with the boiler • Insert the air pipe into the air inlet fitting and give a 1/4 turn
into the air inlet fitting to prevent foreign to ensure coverage. Support until the sealant has dried.
objects from entering the opening.
46 Part number 550-142-056/0411

DIRECT EXHAUST — Boiler room air openings

Combustion air provision Special considerations
The GWC boiler can use inside air if no contaminants are present in the Tight construction
boiler space. (If contaminants are likely to be present, install the boiler
ANSI Z223.1 defines unusually tight construction
as a direct vent appliance, using the appropriate vent instructions in this where:
manual.)
1. Walls and ceilings exposed to the outside atmo-
The boiler room must be fitted with combustion air openings large enough sphere have a continuous water vapor retarder with
to provide air for all appliances in the room. Use the following information a rating of 1 perm or less with openings gasketed,
to size the openings. Ensure the installation complies with all applicable and . . .
codes and standards. 2. Weather-stripping has been added on openable
windows and doors, and . . .
Where the GWC boiler shares a space with other appliances, the combus- 3. Caulking or sealants are applied to areas such as
tion air openings must be sized to handle the combined requirements of joints around windows and door frames, between
all appliances in the space. sole plates and floors, between wall-ceiling joints,
between wall panels, at penetrations for plumbing,
electrical, and gas lines, and in other openings.
Sizing combustion air openings For buildings with such construction, provide air
openings into the building from outside, sized per the
Air openings provide for ventilation (as well as combustion air) to prevent appropriate case in Figure 56, page 48 if appliances are
overheating of the boiler controls and boiler space. Air is also needed for to use inside air for combustion and ventilation.
other appliances located in the same space.
Exhaust fans and air movers
Use Figure 56, page 48, selecting the appropriate installation conditions. The appliance space must never be under a negative
pressure unless all appliances are installed as direct
Air openings must be sized to handle all appliances and air vent. Always provide air openings sized not only to
movers (exhaust fans, etc.) using the air supply. the dimensions required for the firing rate of all appli-
ances, but also to handle the air movement rate of the
The sizing given in Figure 56, page 48 is based on the National Fuel Gas exhaust fans or air movers using air from the building
Code, ANSI Z223.1, allowing adequate air openings for gravity-vented gas or space.
appliances (Category I) in addition to that needed for the GWC boiler.
Motorized air dampers
The air openings recommended in Figure 56, page 48 will allow adequate If the air openings are fitted with motorized dampers,
ventilation and combustion air provided the boiler room is not subjected electrically interlock the damper to:
to negative pressure due to exhaust fans or other mechanical ventilation
• Prevent the boiler from firing if the damper is not
devices.
fully open.
Refer to the National Fuel Gas Code for dealing with other conditions. • Shut the boiler down should the damper close dur-
ing boiler operation.
Free area — louver allowance To accomplish this interlock, wire an isolated contact
(proving the damper open) in series with the thermo-
The free area of openings means the area after reduction for any installed stat input to the boiler. The boiler will not start if this
louvers or grilles. Be sure to consider this reduction when sizing the air contact is open, and will shut down should it open
openings. during operation.
Part number 550-142-056/0411 47

DIRECT EXHAUST — Boiler room air openings (cont.)

Figure 56 MINIMUM combustion air openings for direct exhaust applications — ALL OPENING SIZES ARE FREE AREA
The GWC boiler CANNOT be in the same space with other appliances if If the space is smaller than
clearances around the GWC are less than the recommended service clearances Figure 2, page 6, provide
shown in Figure 2, page 6. openings ONLY as shown on
page 7 and Figure 4, page 7.
Air openings
GWC boiler GWC boiler
The required air opening sizes below are FREE AREA, WITH other WITHOUT other
after reduction for louver obstruction. Note the ex-
ception below for large spaces. appliances in room appliances in room
TWO openings, each at least: TWO openings, each at least:

1 square inch per 1,000 Btuh 1 square inch per 4,000 Btuh
of all appliances in the room of all appliances in the room

— OR — — OR —
ONE opening **, each at least: ONE opening **, each at least:

— OR — — OR —

— OR — — OR —
A single combustion air opening can be used for cases b, c or d above, sized as
listed, provided that:
** NOTICE: • The single opening must communicate directly to the outdoors or to a space that
Requirements for using the SINGLE air opening communicates directly with outdoors (NOT to an interior space).
option. • The top of the opening must be within 12 inches of the ceiling.
• The free area of the opening must be at least equal to the sum of the areas of all
equipment vent connectors in the space.
NO combustion air openings are needed when the boiler (and other appliances) are
installed in a space with a volume NO LESS than 50 cubic feet per 1,000 Btuh of all ap-
pliances in the space. That is, total the input of all appliances in MBH (1,000’s of Btuh),
SPECIAL EXCEPTION FOR LARGE SPACES: then multiply this total times 50. The building MUST NOT be of tight construction.
Example: For a total input of 500 MBH (500,000 Btuh), the minimum volume would be
50 x 500 = 25,000 cubic feet (3,125 square feet if ceiling height is 8 feet).
48 Part number 550-142-056/0411

DIRECT EXHAUST — Sidewall

DO NOT sidewall vent DIRECT EX-
Figure 57 Installation sequence — Direct exhaust sidewall
HAUST APPLICATIONS at altitudes
above 5,500 feet. Sidewall venting is
only allowed for DIRECT VENT ap-
plications (ducted combustion air)
at altitudes above 5,500 feet.
Allowable vent/air pipe materials &

lengths
Use only the vent materials and kits
listed in Figure 40, page 33. Provide
pipe adapters if specified.
1. Locate the termination such that the total air
piping and vent piping from the boiler to the
termination will not exceed the maximum
length given in Figure 39, page 32.

1. The air and vent terminations must be
installed as shown in Figure 57 and in Fig-
ure 58, page 50.
2. The terminations must comply with clearances Step 1 Read and follow all instructions in this manual. DO NOT proceed with
and limitations shown in Figure 41, page 35. vent installation until you have read page 29 through page 35,
page 47 and page 48.
3. Locate the termination so it is not likely to be
Step 2 Install the boiler in a location that allows proper routing of vent piping to
damaged by foreign objects, such as stones the selected sidewall location.
or balls, or subject to buildup of leaves or
sediment. Step 3 Make sure the selected sidewall termination location complies with Fig-
ure 41, page 35.
Step 4 Use only the vent materials listed in Figure 40, page 33. Provide pipe adapt-
Multiple vent/air terminations ers where required. Vent piping length must not exceed the value shown in
1. Terminate each vent of multiple direct exhaust Figure 39, page 32. In addition to the vent materials, this installation
requires two (2) sidewall termination plates and one bird screen,
GWC boilers as described in this manual for unless using an AL29-4C termination fitting with integral screen.
individual vents. Sidewall plates can be made by cutting a W-T sidewall plate in half or can
be fabricated and supplied by the installer. Two two-hole plates and two
2. Space terminations as required for best instal- bird screens are supplied with the boiler.
lation practices and required maintenance.
Step 5 Prepare the sidewall penetration and secure the sidewall plate as instructed
a. External venting greater than 4 feet in this section. See “Prepare wall penetration” on page 49 and “Termination
requires an enclosure around the vent and fittings” on page 50.
pipe. The vent termination must exit Step 6 The vent piping can terminate using a coupling or down-turned elbow, or
through the enclosure as shown in Fig- snorkeled and terminated with an elbow. See illustration above. The coupling
ure 57, page 49, maintaining all required or elbow must butt against the outside plate.
clearances. Step 7 Install vent piping between the boiler and the sidewall opening. Slope
horizontal piping downward toward the boiler at least 1/4 inch per foot.
Prepare wall penetration See page 46 for general guidelines.
Step 8 Install pipe supports every 5 feet on both the horizontal and vertical runs.
In addition to the vent materials, Install a hanger support within 6 inches of any upturn in the piping.
this installation requires two (2) Step 9 Attach the vent termination exterior piping, if used: Use any of the con-
sidewall termination plates and figurations shown above, as needed to ensure clearance above grade or
one (1) bird screen, unless using an snow line.
AL29-4C termination fitting with Step 10 The vent pipe may run up as high as 4 feet with no enclosure. The vent
integral screen. Sidewall plates can pipe must be secured with braces, and all clearances and lengths must be
be made by cutting W-T sidewall maintained. Space braces no further than 24 inches apart.
plates in half or can be fabricated Step 11 External venting greater than 4 feet requires an insulated enclosure around
and supplied by the installer. Two the vent and air pipes. The vent and air terminations must exit through
two-hole plates and two bird screens the enclosure as shown in the illustration above, maintaining all required
are supplied with the boiler for use clearances.
with 3" PVC pipe.
Part number 550-142-056/0411 49

DIRECT EXHAUST — Sidewall (continued)

Where the vent penetrates an outside wall, the annular
Figure 58 DIRECT EXHAUST — Sidewall — termination
space around the penetration must be permanently assembly and termination options — all parts
sealed using approved materials to prevent entry of by installer except where shown otherwise
combustion products into the building.
1. Wall penetration:
a. Cut a rough opening large enough to clear the diameter
of the metal thimble used.
b. The metal plates can be field fabricated or can be made by
cutting a W-T sidewall termination plate in half — two
2-hole plates are supplied with the boiler.
c. The W-T plate hole diameters are 3.14" for holes as is. Use
as is for 3" AL29-4C pipe. Remove knockout to provide
35⁄8" hole for 3" PVC pipe.
d. If field fabricating the plates, the hole diameters in the
metal plates must be 35⁄8” for PVC pipe. For AL29-4C vent
pipe and coupling (or elbow) — size hole large enough to
clear vent pipe, but small enough to prevent the termina-
tion coupling (or elbow) from being pushed through.
e. Insert a galvanized metal thimble (by installer) in the vent
pipe hole as shown in Figure 58.
through floors or walls.

1. If using a coupling or elbow for the termination, prepare the
vent termination fitting (Figure 58, page 50) by inserting a
bird screen, unless using an AL29-4C termination fitting with
integral screen. Bird screens are not supplied with the GWC
boiler. Purchase separately from Williamson-Thermoflo. See
Figure 92, page 87 for part numbers.
2. You can install the vent termination using either of the con-
figurations shown in Figure 57, page 49.
4. Do not extend exposed vent pipe outside of the building more
than shown in this document. Condensate could freeze and
block vent pipe.
LEGEND for Figure 58

1 Vent piping
2 Sidewall termination plates — two 2-hole plates are supplied with the
boiler — one of these can be cut in half for use in direct exhaust venting
or the plate can be field fabricated) — plate holes can be used as is for 3"
AL29-4C vent pipe. Remove knockout to provide clearance hole for 3" PVC
pipe.
3 Galvanized thimble
4 Vent termination elbow
5 Bird screen — two bird screens are supplied with each boiler
6 Extend vent pipe through outside plate enough to attach termination
coupling (or elbow when snorkeled).
7 Snorkel option (to elevate vent termination) — requires bird screen (see
Figure 92, page 87 for part numbers)
8 Coupling option — requires bird screen — two bird screens are supplied
with each boiler
50 Part number 550-142-056/0411

DIRECT EXHAUST — Vertical

Allowable vent/air pipe materials & Figure 59 Installation sequence — Direct exhaust vertical
lengths
ers if specified.
Figure 39, page 32.

1. The vent terminations must be installed as shown
in Figure 59, page 51.
2. The terminations must comply with clearances and
subject to buildup of leaves or sediment.

1. Terminate each vent of multiple direct exhaust
GWC boilers as described in this manual for in-
dividual vents.
2. Space terminations as required for best installation
practices and required maintenance. Step 1 Read and follow all instructions in this manual. DO NOT
proceed with vent/air installation until you have read
page 29 through page 35, page 47 and page 48.
Prepare roof penetration
1. Vent pipe penetration: Step 2 Install the boiler in a location that allows proper routing of
a. Cut a hole for the vent pipe. For either com- all vent and air piping to the selected sidewall location.
bustible or noncombustible construction, size Step 3 Make sure the selected vertical termination location com-
the vent pipe hole at least 0.5” larger than the plies with Figure 41, page 35.
vent pipe diameter.
Step 4 Use only the vent materials listed in Figure 40, page 33.
b. Hole diameter in the metal plates must be at
least 4” for PVC pipe. For AL29-4C vent pipe Provide pipe adapters where required. Vent piping and air
and coupling (or elbow) — size hole 0.5” larger piping lengths must not exceed the values shown in Fig-
than vent pipe outside diameter. ure 39, page 32.
c. Insert a galvanized metal thimble in the vent Step 5 Prepare the vertical penetration and secure penetration
pipe hole. components as instructed in this section. See “Prepare roof
2. Follow all local codes for isolation of vent pipe when penetrations” on page 41 and “Termination and fittings” on
passing through floors, ceilings and roofs. page 42.
3. Provide flashing and sealing boots sized for the vent Step 6 The vent piping must terminate in a coupling pointed
pipe and air pipe. upward as shown above. Fit the coupling with a bird screen
as shown. Two bird screens are supplied with the boiler.
Where the vent penetrates the roof, the an-
nular space around the penetration must Step 7 Install vent and air piping between the boiler and the verti-
be permanently sealed using approved cal termination. Slope horizontal piping downward toward
the boiler at least 1/4 inch per foot. Install pipe supports
materials to prevent entry of combustion every 5 feet on both the horizontal and vertical runs. Install
products into the building. a hanger support within 6 inches of any upturn in the pip-
ing. See page 46 for general guidelines.
Step 8 Maintain minimum clearance of C\zn inch between vent pipe
and any combustible wall or material.
Step 9 Insert the vent piping through the vertical penetration and
secure the termination coupling.
Step 10 Maintain clearances shown above. Vent terminations must
be fitted with a bird screen as shown. See Figure 92, page 87
for part numbers.
Part number 550-142-056/0411 51

Gas piping
Connecting gas supply piping Figure 60 Gas supply connection to GWC boiler gas manifold
Do not connect gas supply to boiler or at-
tempt to operate boiler unless the correct
orifice plate has been verified or installed
in accordance with page 8.
Except where otherwise instructed in
this manual, do not attempt to measure
or adjust the outlet pressure setting of
the gas valve. The gas valve is factory
set to a slight negative pressure, and is
operated as a negative-pressure regulated
valve.
Failure to comply will result in malfunc-
tion of the boiler, causing severe personal
damage.
1. Refer to Figure 60 to connect gas supply to ½” NPT
boiler gas connection. Use wrench to hold factory-
installed gas cock.
2. Support piping with hangers, not by boiler or its
accessories.
3. Purge all air from gas supply piping.
4. Before placing boiler in operation, check boiler and
test all gas connections for leaks.
Do not check for gas leaks with an
open flame — use bubble test. Failure
to use bubble test or check for gas leaks
can cause severe personal injury, death or
Close manual main shutoff valve dur-
ing any pressure testing at less than
13” w.c.
Disconnect boiler and gas valve from
gas supply piping during any pressure
testing greater than 13” w.c.
5. Use pipe dope compatible with propane gases.
Honeywell VK8115V gas valve
Apply sparingly only to male threads of pipe joints
so that pipe dope does not block gas flow. • The Honeywell VK8115V gas valve operates with DC voltage.
Failure to apply pipe dope as detailed • The black power plug that connects to the gas valve contains
above can result in severe personal injury, a DC rectifier.
death or substantial property damage. • When the gas valve is energized, approximately 19 to 21 volts
DC voltage should be measured across the two outer pins of the
gas valve connector plug.
• There are 4 pins on the gas valve and 3 pin receptacles in the plug.
Only the two outer pins are used for powering the valve.
• To measure voltage, remove the screw and slightly lift the plug
until meter leads can touch end pins.
• Run boiler and test for proper voltage.
• Remember to re-install plug and tighten screw after testing.
Continuity cannot be checked in the gas valve con-
nector plug wiring due to the rectifier.
52 Part number 550-142-056/0411

Gas piping (continued)

Natural Gas Figure 61 Pipe capacity for 0.60 specific gravity natural gas
1. Refer to Figure 61 for pipe length and diameter.
Size gas supply piping for total flow to all connected Capacity in cubic feet of gas per hour
appliances. For each GWC boiler, provide for the Natural gas only, with specific gravity of 0.60
following gas flow (cfh = cubic feet per hour): Gas pipe Based on pressure drop of 0.3” w.c.
length
Boiler model CFH natural gas
(feet) Gas pipe diameter —
GWC-070 70
GWC-105 105 ½” ¾” 1” 1¼” 1½”
GWC-140 140
10 132 278 520 1050 1600
GWC-175 175
20 92 190 350 730 1100
2. Inlet pressure required at gas valve inlet:

30 73 152 285 590 860
• maximum 13” w.c.
• minimum 4” w.c.
40 63 130 245 500 760
Install 100% lockup gas pressure regula-
tor in supply line if inlet pressure exceeds
13” water column. Adjust for 13” w.c. 50 56 115 215 440 670
maximum.
75 45 93 175 360 545
Propane Gas 100 38 79 150 305 460

1. Contact gas supplier to size pipes, tanks and 100%
lockup gas pressure regulator. 150 31 64 120 250 380
2. Adjust propane supply regulator provided by gas
supplier for 13” w.c. maximum pressure. For additional gas pipe sizing information, refer to ANSI Z223.1 (or
3. Inlet pressure required at gas valve inlet: B149.1 orB149.2 for Canadian installations).
• maximum 13” w.c.
• minimum 4” w.c.
Part number 550-142-056/0411 53

Wiring
For your safety, turn off electrical power supply at service
Figure 62 Field wiring connections — service switch
entrance panel before making any electrical connections and thermostat (or end switch) provided
to avoid possible electric shock hazard. Failure to do so by installer
can cause severe personal injury or death.
Installation must comply with:

National Electrical Code and any other national, state, provincial or
local codes or regulations. In Canada, CSA C22.1 Canadian Electrical
Code Part 1, and any local codes. Boiler must be electrically grounded as
required by National Electrical Code ANSI/NFPA 70-latest edition.
Wiring must be N.E.C. Class 1. Boiler must be electrically

grounded as required by National Electrical Code ANSI/
NFPA 70-latest edition.
To replace wiring, order complete harness assemblies

from Williamson-Thermoflo. If any original wiring as
supplied with boiler must be replaced, and a harness is
not immediately available, use only type 105°C wire or
equivalent. Use this wiring only as a temporary repair.
Obtain a complete harness from Williamson-Thermoflo.
When using three-wire zone valves, take care
to avoid mis-wiring. This can impose an ad-
Wiring connections ditional 24 volts across the boiler control circuitry. The IBC
will sense this problem and lockout. It will flash the POW-
ER and TSTAT CIRC lights to indicate the problem. See
Power wiring
label on IBC for explanation of lockout conditions. To
Connect 120 VAC power wiring as shown in Figure 62. The junction verify before connecting to boiler, disconnect field thermo-
box is located on the inside left jacket panel. stat wires at boiler. Place a voltmeter across the leads. Then
watch the voltmeter as each zone is activated (by activating
zone thermostat). There should never be a voltage reading
Watch the polarity of the circuit when connecting the across the two leads coming to the boiler. If you see a volt-
120 VAC power wiring. If the polarity is switched, the age reading, one or more zone valves is mis-wired.
integrated boiler control will lockout. The IBC will
flash the POWER light to indicate this problem. See the Carbon monoxide detector
troubleshooting information beginning on page 73.
For Direct Exhaust units, a carbon monoxide
detector is required in the boiler room. The
Additional limit controls carbon monoxide detector must be wired on
the same electrical circuit as the boiler. For
Wire additional limit controls (if used) as shown in Figure 63. Direct Vent units, a carbon monoxide detector
that is wired on the same electrical circuit as
Thermostat(s) the boiler is strongly recommended.
Install thermostats on inside walls, away from influences of drafts,

hot or cold water pipes, lighting fixtures, television, sun rays, or fire-
places.
Figure 63 Wiring location for additional limit controls
Follow instructions with thermostat. If it has a heat anticipator, set heat
anticipator in thermostat to match power requirements of equipment
connected to it (ignition control and gas valve, zone valve contacts,
etc.). Wiring diagram on boiler gives setting for standard equipment
(ignition control and gas valve).
Thermostat wires are labeled “T-T” on boiler. Remove label before

connecting as shown in Figure 62. Route this wiring through the hole
in the upper left side jacket.
For zoned systems, substitute the zone valve end switches or circulator
relay contacts for the thermostat contact shown in Figure 62.
54 Part number 550-142-056/0411

Wiring (continued)
Figure 64 Ladder wiring diagram
Part number 550-142-056/0411 55

Wiring (continued)
Figure 65 Schematic wiring diagram
56 Part number 550-142-056/0411

Start-up
Eliminate all system leaks. Continual fresh makeup water
Figure 67 Freeze protection guidelines
will reduce boiler life. Minerals can build up in sections,
reducing heat transfer, overheating cast iron, and causing
Freeze protection (when used) section failure.
Follow these guidelines to prevent possibility Clean system to remove sediment

of severe personal injury, death or substantial
1. You must thoroughly flush the system (without boiler connected)
property damage:
to remove sediment. Sediment can affect chemical treatment of the
NEVER use automotive or standard glycol system and can damage system components.
antifreeze, even glycol made for hydronic 2. For zoned systems, flush each zone separately through a purge
valve. (If purge valves and isolation valves are not already installed,
systems. Use only freeze-prevention fluids
install them to properly clean the system.)
recommended by Williamson-Thermoflo for
3. Flush system until water runs clean and you are sure piping is free
application in GWC Boiler systems.
of sediment.
Thoroughly flush any system that has
used glycol before installing the new GWC Water chemistry
boiler.
Review the material safety data sheet Using softened water — Softened water can be corro-
sive. Pay special attention to the inhibitor level, follow-
(MSDS) for the fluid used with the boiler ing the instructions in this manual and those supplied
owner and leave a copy for reference. The with the inhibitor.
MSDS contains information on potential
Water chemistry must be within the limits listed in
hazards and first aid procedures for exposure
the following. If the water differs in any way, consult
or ingestion. a water treatment company to set up a treatment pro-
gram to control the system water within these limits at
Check antifreeze inhibitor level at least the time of initial fill and throughout system operating
annually. Glycol concentration and inhibitor life.
levels may change over time. Add antifreeze
Failure to maintain water chemistry as specified can
to increase concentration if necessary. Add result in damage to the boiler and system components,
inhibitor as needed to bring to acceptable resulting in potential for severe personal injury, death
level, using inhibitor test kit to verify. or substantial property damage.
When using freeze protection fluid with au-

tomatic fill, install a water meter to monitor Water pH: Minimum = 7.0 | Maximum = 8.5
water make-up. Freeze protection fluid may 1. Maintain boiler water pH between 7.0 and 8.5. Check with litmus
leak before the water begins to leak, causing paper or have chemically analyzed by water treatment company.
concentration to drop, reducing the freeze
Hardness: Maximum = 6.0 grains per gallon
protection level.
1. The water hardness must comply with the maximum value above.
DO NOT exceed 50% antifreeze by volume. High hardness will cause scale accumulation.
Antifreeze moves more sluggishly than wa- Chlorine: Maximum 200 ppm
ter and can interfere with heat transfer. At
1. Filling with chlorinated fresh water should be acceptable since
antifreeze concentrations higher than 50%, drinking water chlorine levels are typically less than 5 ppm.
sludge can develop in the boiler, potentially 2. Do not use the boiler to directly heat swimming pool or spa
causing damage to the heat exchanger. water.
Clean the system before filling. Always 3. Do not fill boiler or operate with water containing chlorine in
excess of 200 ppm.
drain and flush the system thoroughly before
filling with antifreeze. Sludge, iron oxide
deposits and other sediment in the system Antifreeze
inhibit flow and can cause rapid breakdown 1. Use only antifreeze listed by Williamson-Thermoflo as suitable
of inhibitors. for use with GWC boilers. A list of approved antifreeze products
is available at www.Williamson-Thermoflo.com.
Part number 550-142-056/0411 57

Start-up (continued)
2. Close the boiler or system isolation valve between the
purge valve and fill connection to the system.
Check for gas leaks
3. Close zone isolation valves.
Before starting the boiler, and during initial opera- 4. Open quick-fill valve on cold water make-up line.
tion, use a leak detector or smell near the floor and 5. Open purge valve.
around the boiler for gas odorant or any unusual
odor. Remove boiler front door and smell interior 6. One zone at a time, open the isolation valves. Allow
of boiler enclosure. Do not proceed with startup water to run through the zone, pushing out the air. Run
if there is any indication of a gas leak. Repair any until no noticeable air flow is present. Close the zone
leak at once. isolation valves and proceed with the next zone. Follow
this procedure until all zones are purged.
DO NOT adjust or attempt to measure gas valve 7. Close the quick-fill water valve and purge valve and
outlet pressure except where instructed specifi- remove the hose. Open all isolation valves. Watch that
cally in this manual. This setting is suitable for system pressure rises to correct cold-fill pressure.
natural gas and propane, requiring no field ad- 8. After the system has operated for a while, eliminate
justment. Attempting to alter or measure the gas any residual air by using the manual air vents located
valve outlet pressure without following the correct throughout the system.
procedures could result in damage to the valve, 9. If purge valves are not installed in system, open manual
causing potential severe personal injury, death or air vents in system one at a time, beginning with lowest
substantial property damage. floor. Close vent when water squirts out. Repeat with
remaining vents.
Propane boilers only — Your propane supplier
10. Open automatic air vent (diaphragm-type or bladder-
mixes an odorant with the propane to make its type expansion tank systems only) one turn.
presence detectable. In some instances, the odor-
ant can fade, and the gas may no longer have an 11. Starting on the lowest floor, open air vents one at a time
odor. Before startup (and periodically thereafter), until water squirts out.
have the propane supplier verify the correct odor- 12. Repeat with remaining vents.
ant level in the gas.
Pressurize system
1. Close manual and automatic air vents and boiler drain
valve.
2. See Replacement parts at the end of this manual for Williamson-
Thermoflo part numbers to obtain antifreeze through a William- 2. Fill system to correct system pressure. Correct pressure
son-Thermoflo distributor. will vary with each application.
a. Typical cold water fill pressure for a residential
Use the correct amount of antifreeze system is 12 psi (when using a 30 PSIG boiler relief
valve).
1. Determine the freezing temperature needed (to protect against
lowest likely temperature the system water will encounter). b. Pressure will rise when boiler is turned on and sys-
tem water temperature increases. Operating pressure
2. Find the antifreeze concentration by volume needed for this tem- must never exceed 5 PSIG less than the boiler relief
perature from the antifreeze manufacturer’s data on the antifreeze valve setting.
container. 3. At initial fill and during boiler startup and testing, check
3. Add up the volume (gallons) of all system piping and components, system thoroughly for any leaks. Repair all leaks before
including the expansion tank and boiler. proceeding further.
a. Boiler water content is listed in Figure 105, page 99.
b. Remember to include expansion tank water content. Eliminate all system leaks. Continual fresh
make-up water will reduce boiler life. Minerals
4. Multiply this volume by the (percent) antifreeze needed to find the
can build up in sections, reducing heat trans-
number of gallons of antifreeze to add. fer, overheating heat exchanger, and causing
heat exchanger failure.
Fill and test water system
1. Fill system only after ensuring the water meets the requirements Use inhibitor supplied with boiler
of this manual.
1. The GWC boiler is shipped with Sentinel X100 inhibitor
Purge air from water system and Sentinel inhibitor test kit. See Replacement parts
at the end of this manual for re-ordering information.
1. Connect a hose to the purge valve (see purge/drain valves in piping
diagrams beginning with Figure 17, page 16. Route hose to an area 2. After filling the system as directed in these instructions,
where water can drain and be seen. use a caulking gun to inject the X100 inhibitor into the
system, following the instructions on the tube.
58 Part number 550-142-056/0411

3. Inject all of the inhibitor supplied with the boiler. Allow time for 5. Once the external thermostat circuit wiring is checked
the water to circulate and mix. Then check the inhibitor level. Add and corrected if necessary, reconnect the external ther-
additional inhibitor if necessary. mostat circuit wires. Allow the boiler to cycle.
Check/verify water chemistry Inspect/fill condensate system

1. The system may have residual substances that could affect water
chemistry. Inspect/check condensate lines and fittings
2. After the system has been filled and leak tested, verify water pH 1. Inspect the condensate drain line, condensate PVC fit-
and chlorine concentrations are acceptable. tings and condensate trap.
3. Verify antifreeze concentration, when used. Fill condensate trap with water
4. Follow the instructions on the Sentinel test kit to sample the system 1. Loosen the hose clamp (Figure 66, item 2) that secures
water and verify inhibitor concentration. the condensate trap (Figure 66, item 1) to the bottom
of the recuperator (Figure 66, item 3).
Check inhibitor concentration annually 2. Pull the condensate trap tube off of the recuperator
condensate drain nipple.
1. Test the pH of a sample of system water at least annually. The pH
of the water mixture must be between 7.0 and 8.5. (Or use the 3. Use a funnel to feed water into the top of the conden-
Sentinel inhibitor test kit to check concentration.) sate tube.
2. If pH is outside this range (or inhibitor test kit indicates low level), 4. Continue filling until water begins to flow out through
the inhibitor level may not be sufficient to prevent corrosion. the condensate line (Figure 66, item 4).
3. Test antifreeze concentration. 5. Re-attach the condensate trap to the bottom of the
recuperator. Secure with the hose clamp.
Test antifreeze concentration at least annually. If concen- 6. Check for any leaks in the condensate drain line or fit-
tration is low, add antifreeze or drain system and refill tings. Repair any leaks.
with correct mixture.
7. Remove the temporary clamp (see step 2, above) from
4. Follow instructions on antifreeze container to determine the the condensate drain tube.
amount of antifreeze needed. DO NOT exceed 50% by volume
concentration of antifreeze. The condensate trap must be filled with water
during all times of boiler operation to avoid
5. Check inhibitor level after adjustments are made. flue gas emission from the condensate drain
line. Prime the condensate trap by pouring
Verify gas/air orifice plate water into the outlet tee while restricting flow
in drain tube if boiler has been out of service
The proper orifice plate must be used. Failure to do for an extended period. Failure to fill the trap
so will cause severe personal injury, death or substantial could result in severe personal injury or death.
property damage.
1. Remove the jacket front panel.
Figure 66 Condensate trap assembly
2. Read the boiler size written on the gas/air orifice label tab, verifying
the correct size. See Figure 5, page 8 for details.
3. The orifice plate must be plain aluminum for natural gas. For
propane gas, the exposed tab of the plate should be red.
4. Replace the orifice plate if necessary, following the guidelines on
page 8.
Check thermostat circuit(s)

1. Disconnect the two external wires connected to the boiler thermo-
stat terminals (see Field wiring, beginning on page 54 for terminal
locations).
2. Connect a voltmeter across these two incoming wires. Close each
thermostat, zone valve and relay in the external circuit one at a
time and check the voltmeter reading across the incoming wires.
3. There should NEVER be a voltage reading.
4. If a voltage does occur under any condition, check and correct the
external wiring. (This is a common problem when using 3-wire
zone valves.)
Part number 550-142-056/0411 59

Final checks before starting boiler Figure 68 Check for igniter glow by looking into
observation port on front of blower
❏❏ Review the boiler sequence of operation in Figure 71, page 63. housing
❏❏ Verify that the boiler and system are full of water and all system
components are correctly set for operation.
❏❏ High altitude locations (over 5,500 feet) — verify that the high
altitude pressure switch is installed per page 10.
❏❏ Verify that condensate trap has been filled with water.

❏❏ Verify electrical connections are correct and securely attached.
❏❏ Inspect vent piping and air piping for signs of deterioration from
corrosion, physical damage or sagging. Verify air piping and vent
piping are intact and correctly installed per this manual.
To start the boiler

1. Turn OFF the boiler ON/OFF switch.
2. Read and follow the Operating Instructions, Figure 72, page 64.
If boiler does not start correctly If you discover evidence of any gas leak, shut
down the boiler at once. Find the leak source
1. Check for loose connections, blown fuse or service switch off? with bubble test and repair immediately. Do
2. Is external limit control (if used) open? Is boiler water temperature not start boiler again until corrected. Failure
above boiler limit setting? to comply could result in severe personal
3. Is thermostat set below room temperature?
4. Is gas turned on at meter or boiler? ❏ Check the igniter
5. Is incoming gas pressure less than 4” w.c.? 1. Inspect the igniter to verify operation as shown in Fig-
6. If none of the above corrects the problem, refer to Troubleshooting, ure 68. The igniter glow may be difficult to see clearly,
beginning on page 73. depending on room lighting.
Check system and boiler after start-up Gas valve adjustment — altitude
over 5,500 feet ONLY
❏ Check water piping Apply the following only when:
1. Check system piping for leaks. If found, shut down boiler and • Altitude is over 5,500 feet above sea level.
repair immediately. (See WARNING on page 58 regarding failure • You have obtained a high altitude kit (with tools needed)
to repair leaks.) and installed high altitude air pressure switch per the
2. Vent any remaining air from system using manual vents. Air in the instructions on page 10.
system will interfere with circulation and cause heat distribution • Boiler has started correctly, following procedures on
problems and noise. previous pages.
You will need the tools shown in Figure 69. Adjust the gas
❏ Check vent piping and air piping valve outlet pressure only if required as described in the
1. Check for gas-tight seal at every connection and seam of air piping following instructions.
and vent piping.
Connect and adjust manometer
Venting system must be sealed gas-tight to prevent flue 1. Remove boiler jacket top and front panels.
gas spillage and carbon monoxide emissions which will
result in severe personal injury or death. 2. Close manual gas supply valve and turn off electrical
power to boiler.
❏ Check gas piping 3. Using common bit screwdriver, remove outlet pressure
tap plug from gas valve and save plug (Figure 70).
1. Check around the boiler for gas odor following the procedure of 4. Place the negative side of the manometer hose over end
page 52 of this manual. of outlet pressure tap barrel.
60 Part number 550-142-056/0411

5. Position and zero manometer per manufacturer’s instructions. The
Figure 69 Tools required for gas valve outlet
manometer must have at least 6” of tubing above the fluid level or pressure measurement
fluid may be drawn into the gas valve.
If manometer fluid is drawn into gas valve body, gas valve
must be replaced. Fluid in valve will cause it to malfunc-
tion, possibly resulting in severe personal injury, death
or substantial property damage.
6. Disconnect tube from hose barb on gas valve vent tap. Connect
tube end to tee hose fitting as shown in Figure 70. Then add length
of hose from tee hose fitting to gas valve vent tap.
7. Connect positive side manometer hose to top of the tee hose fit-
ting (Figure 70).
1 U-tube manometer with tubing - 3 1/16" flat head screw-
8. Connect negative side manometer hose to the barrel of the gas Manometer provides a fine scale by driver.
valve outlet pressure tap (Figure 70). slanting the manometer (Dwyer Model 4 T-40 star drive for
1227 recommended).
Check gas valve setpoint gas valve pressure
2 Tee hose fitting (provided in high regulator cover
1. Open manual gas valve and turn on electrical power to boiler.
altitude kit). screw.
2. Start boiler and allow boiler to run for 5 minutes.
3. Read manometer. This is the gas valve outlet pressure set point. If
set point is between – 0.1” w.c. and – 0.3” w.c. go to step 7. Figure 70 Carefully connect manometer to gas valve
as shown, following instructions on this
4. If gas valve setpoint is not between – 0.1” w.c. and – 0.3” w.c., use page (see legend at left)
T-40 driver to remove cap on gas valve pressure regulator.
5. Turn gas valve pressure regulator screw counter clockwise to
lower gas valve set point to – 0.2” w.c.
6. Reinstall cap on gas valve pressure regulator using T-40 driver.
7. Cycle boiler off and on several times to verify gas valve set point.
If set point does not remain between - 0.1” w.c. and – 0.3” w.c.,
readjust as necessary.
8. Close manual gas supply valve and turn off electrical power to
boiler.
9. Remove manometer hose from gas valve outlet pressure tap barrel
and replace sealing screw.
10. Remove tee hose fitting and added tube.
11. Reinstall hose on gas valve vent tap hose barb.
12. Open manual gas supply valve and turn on electrical power to
boiler.
Legend for Figure 70

1 Gas control outlet pressure tap — located on back side of gas control. Use tap
closest to gas control gas outlet —Remove screw from gas control outlet pressure
tap and slide hose over tap
2 Add tee hose fitting as shown
3 Existing hose to gas control vent tap hose barb — Remove from gas control vent
tap and connect to end of tee as shown
4 Gas control pressure regulator cap
5 Honeywell Type VK8115V gas valve
6 Gas outlet vent tap
7 Gas outlet piping
8 Add hose from gas control vent tap to tee hose fitting
Part number 550-142-056/0411 61

Final checklist ❏❏ Test additional field-installed controls — If boiler has a
low water cutoff, additional high limit or other controls,
test for operation as outlined by manufacturer. Burner
Use the checklist following to ensure boiler is should be operating and should go off when controls
are tested. When controls are restored, boiler should
operating correctly. restart.
Have the following been completed? ❏❏ Test ignition system (integrated boiler control):
❏❏ Is proper orifice plate installed? Refer to page 8 to check size and f. Connect voltmeter to gas valve terminals.
fuel type.
g. Turn off manual gas valve.
Proper orifice plate must be used. Failure to do so will h. Set thermostat to call for heat.
cause severe personal injury, death or substantial prop-
erty damage. i. IBC will begin purge cycle, then activate igniter.
Igniter will glow for approximately 20 seconds.
Near end of 20 seconds, 24 VDC will show at gas
❏❏ Thermostat heat anticipator (if available) set properly? Refer to valve for approximately 6 seconds and then return
Field wiring, page 54. to 0 VDC. Control will attempt ignition two more
times, increasing igniter time to 30 seconds for these
attempts. The control will then lockout, flashing the
❏❏ Read and followed all procedures and checks specified in the Start- POWER and FLAME lights.
up section, beginning with page 57?
j. To restart system, follow Operating instructions on
boiler (also Figure 72, page 64). (Control will reset
Perform the following after power has been off for at least 45 seconds.)
❏❏ Inspect vent system for leaks. Verify vent (and air) piping are ❏❏ Set limit control(s) to system temperature requirements.
functional and unobstructed. Adjust balancing valves and controls to provide design
temperature to system.
❏❏ Measure natural gas input:
❏❏ For multiple zones, adjust flow so it is about the same
a. Operate boiler 10 minutes. in each zone or as required.
b. Turn off other appliances.
c. At natural gas meter, measure time (in seconds) required to ❏❏ Cycle boiler with thermostat — Raise to highest setting
use one cubic foot of gas. and verify boiler goes through normal start-up cycle.
Lower to lowest setting and verify boiler goes off.
d. Calculate gas input:
❏❏ Observe several operating cycles for proper operation.
3600 x 1000
= Btuh
number of seconds from step c
❏❏ Set room thermostat to desired room temperature.
e. Btuh calculated should approximate input rating on boiler
rating label. ❏❏ Fill in Installation and service certificate (see back cover
of manual).
❏❏ Test limit control — While burner is operating, move indicator
on limit control below actual boiler water temperature. Blower ❏❏ Review all instructions shipped with this boiler with
and burner should go off while circulator continues to operate. owner or maintenance person. Return instructions to
Raise setting on limit control above boiler water temperature and envelope and give to owner or place in pocket inside
burner should reignite. front panel in boiler.
62 Part number 550-142-056/0411

Figure 71 Integrated boiler control (IBC) sequence of operation — status light indications
STEPS Call for POWER TSTAT LIMIT PRESS FLAME Timing

Heat? CIRC SWITCH
(After Step 8, the cycle goes back to Step 1)
1. Standby
NO —
• Waiting for call for heat
2. Call for heat

YES —
• Circulator on
3. Limit circuit
• Limit controls closed
YES —
• Block switch contacts closed
• Blower on
4. Pressure circuit
• Pressure switch contacts closed YES 30 sec
• Ignitor glows
5. Flame proven
• Gas valve open YES 6 sec
• Ignitor remains on
6. Limit cycle
• Limit circuit open
YES 30 sec
• Gas valve closed
• Blower off after postpurge
7. Flame outage *
YES —
• Flame out
8. Thermostat satisfied
• Circulator off
NO 30 sec
• Blower postpurge
• Return to Step 1
= ON = OFF
* If flame is not proven in 4 seconds, boiler recycles 2 times to retry for ignition before going into lockout. Recycle igniter timing
is 30 seconds. Postpurge and prepurge are performed on every cycle. In event of lockout, ignition control will automatically
restore sequence of operation after either:
• 1 hour waiting period.
• Opening and closing of thermostat circuit.
• Removal of 120 VAC power for at least 45 seconds
Part number 550-142-056/0411 63

Figure 72 Operating instructions
64 Part number 550-142-056/0411

Annual start-up and general maintenance schedule

Figure 73 Service and maintenance schedules
Service technician Owner maintenance

(see following pages for instructions) (see following pages for instructions)
General:
• Address reported problems, page 66.
• Check boiler area
• Inspect boiler area, page 66.
Daily • Check air openings
• Inspect boiler interior, page 66.
• Check pressure gauge
• Inspect condensate drain system, page 66.
• Inspect all piping for leaks, page 66.
• Inspect gas piping, page 66.
• Inspect the water system, page 66. • Check boiler interior piping
• Check water system chemistry, page 66 • Check venting system
• Inspect expansion tank, page 67.
Monthly • Check air vents
• Inspect air openings, page 67. • Check condensate drain system
• Inspect vent system and air piping, • Check relief valve
page 67.
Annnual start-up
• Inspect boiler heating surfaces, page 67.

• Inspect igniter, page 67.
• Inspect recuperator, page 68.
• Test low water cutoff (if used)
• Inspect temperature mixing system,
page 68. Periodically • Clean vent termination/air intake
screens
• Inspect limit controls and cutoffs, page 68.
• Inspect gauges, page 68.
• Inspect blower motor, page 68.
• Inspect oiled-bearing circulators, page 68.
• Inspect boiler relief valve, page 69.
• Oil blower motor
Additional if combustion or Every 6 months
• Operate relief valve
performance indicates the need:
• Follow procedures under Cleaning boiler
heating surfaces, page 70 to access boiler
components listed below.
• Clean heat exchanger.
• Remove and clean burner using
compressed air only.
• Vacuum the blower. End of season • Shut down procedure
Review:
• Review with owner.
The boiler contains ceramic fiber Follow the service and maintenance procedures given throughout
and fiberglass materials. Use care this manual and in component literature shipped with the boiler.
when handling these materials per Failure to perform the service and maintenance could result in
instructions on page 103 of this damage to the boiler or system. Failure to follow the directions
manual. Failure to comply could in this manual and component literature could result in severe
result in severe personal injury. personal injury, death or substantial property damage.
Part number 550-142-056/0411 65

Annual start-up
Inspect all piping for leaks
Annual start-up only by qualified
service technician Eliminate all system or boiler leaks. Continual
fresh make-up water will reduce boiler life.
Minerals can build up in sections, reducing
The boiler should be inspected and started annu- heat transfer, overheating heat exchanger, and
ally, at the beginning of the heating season, only causing heat exchanger failure. Leaking water
by a qualified service technician. In addition, the may also cause severe property damage.
maintenance and care of the boiler designated in
Figure 73, page 65 and explained on the follow- 1. Inspect all water and gas piping and verify to be leak
ing pages must be performed to assure maximum free.
boiler efficiency and reliability. Failure to service 2. Look for signs of leaking lines and correct any problems
and maintain the boiler and system could result found.
in equipment failure.
3. Check gas line using procedure on page 52.
Electrical shock hazard — Turn off power to
the boiler before any service operation on the
boiler except as noted otherwise in this instruction Inspect gas piping
manual. Failure to turn off electrical power could
result in electrical shock, causing severe personal 1. Sniff near floor and around boiler area for any indica-
injury or death. tion of a gas leak.
2. Test gas piping using bubble test, per page 52, if
there is any indication of a leak.
Address reported problems
1. Inspect any problems reported by owner and correct before pro- Inspect the water system
ceeding.
1. Verify all system components are correctly installed and
operational.
Inspect boiler area 2. Check the cold fill pressure for the system. Verify it is
correct (usually around 12 PSIG).
1. Verify that boiler area is free of any combustible materials, gasoline
and other flammable vapors and liquids. 3. Watch the system pressure as the boiler heats up (dur-
ing testing) to ensure pressure doesn’t rise too high.
2. Verify that air intake area is free of any of the contaminants listed Excessive pressure rise indicates expansion tank sizing
in Figure 36, page 30. If any of these are present in the boiler intake or performance problem.
air vicinity, they must be removed. If they cannot be removed,
reinstall the air and vent lines per this manual. 4. Inspect automatic air vents and air separators. Remove
air vent caps and briefly press push valve to flush vent.
Reinstall caps. Make sure vents do not leak. Replace any
Inspect boiler interior leaking vents.
1. Remove jacket top and front door to inspect interior of boiler.

Check water system chemistry
2. Vacuum any sediment and components.
1. Check system water chemistry (pH and hardness). See
Do not use solvents to clean any of the boiler compo- instructions beginning on page 57.
nents. The components could be damaged, resulting in
unreliable or unsafe operation. 2. Check glycol and glycol inhibitor levels if using glycol/
water mixture. See instructions beginning on page 57.
3. Check Sentinel X100 inhibitor level in the water using
Inspect condensate drain system the Sentinel X100 Inhibitor Test Kit. Follow instructions
supplied with the kit. Add X100 inhibitor if needed to
1. Inspect the condensate trap hose for deterioration. bring to the correct level. (See Figure 92, page 87 for
2. Check for any obstructions in the trap hose by squeezing the tubing. part numbers.)
3. If there is any doubt the condensate drain system is flowing freely, Do not use petroleum-based cleaning or
remove the clamp and hose from the bottom of the recuperator. sealing compounds in boiler system. Se-
Slide a funnel outlet into the trap hose and pour water through. It vere damage to boiler will occur, resulting in
should exit at the termination of the condensate drain line. substantial property damage.
66 Part number 550-142-056/0411

Annual start-up (continued)

Inspect expansion tank Figure 74 Igniter observation port in blower
1. Expansion tanks provide space for water to move in and out as the
heating system water expands due to temperature increase or contracts
as the water cools. Tanks may be open, closed or diaphragm or bladder
type. See page 13 of this manual for suggested location of expansion
tanks and air eliminators.
• Open-type — located above highest radiator or baseboard unit,
usually in the attic or closet. Has a gauge glass and overflow pipe
to a drain.
• Closed-type — welded gas tight and located above boiler. Tank is
partially filled with water, leaving an air cushion for expansion.
• Make sure this type of tank is fitted with a tank fitting, such
as the B & G Tank-Trol or Taco Taco-Trol. This fitting reduces
gravity circulation of air-saturated tank water back to the system
and prevents the air from bubbling up through the water as it
returns from the system.
• Do not use automatic air vents in systems with closed-type
tanks. The air will escape from the system instead of returning to
the tank. Eventually, the tank will waterlog and no longer control
pressurization. The boiler relief valve will weep frequently.
• Diaphragm- or bladder-type — welded gas tight with a rubber
membrane to separate the tank pressurizing air and the water. May
be located at any point in the system, but most often found near Inspect boiler heating surfaces
the boiler. The boiler contains ceramic fiber and
• Systems with this type of expansion tank require at least one fiberglass materials. Use care when han-
automatic air vent, preferably located on top of an air elimina- dling these materials per instructions
tor, as shown in examples in this manual. on page 103 of this manual. Failure to
2. If relief valve has tended to weep frequently, the expansion tank may comply could result in severe personal
be waterlogged or undersized. injury.
• Closed-type tank — tank is most likely waterlogged. Install a Electrical shock hazard — Turn off
tank fitting if not already installed. Then check fill level per fitting power to the boiler before any service
manufacturer’s instructions. If fill level is correct, check tank size
operation on the boiler except as noted
against manufacturer’s instructions. Replace with a larger tank if
necessary. otherwise in this instruction manual.
Failure to turn off electrical power could
• Diaphragm- or bladder-type — first, check tank size to be sure it result in electrical shock, causing severe
is large enough for the system. If size is too small, add additional
tank (or tanks) as necessary to provide sufficient expansion. If tank personal injury or death.
size is large enough, remove tank from system and check charge 1. Remove the jacket top panel and jacket front panel
pressure (usually 12 PSIG for residential applications). If tank won’t after turning off power to the boiler.
hold pressure, membrane has been damaged. Replace tank. 2. Remove the two nuts retaining the flueway in-
spection port cover (page 3, item g). Remove the
Inspect air openings flueway inspection port cover.
3. Inspect the boiler vent outlet area and heating
1. Verify that combustion and ventilation air openings to the boiler room surfaces by looking through the opening.
and/or building are open and unobstructed. Check operation and wir-
ing of automatic combustion air dampers, if used. 4. If the boiler flueways show accumulation of soot,
follow Cleaning boiler heating surfaces on
2. Verify that boiler vent discharge and air intake are clean and free of page 70 to remove the blower housing and clean
obstructions. the boiler. If there is evidence of a large accumula-
tion of rusty scale deposits, check the temperature
Inspect vent system and air piping mixing system.
5. Replace the flueway inspection port cover.
1. Visually inspect entire flue gas venting system and combustion air pip-
ing for blockage, deterioration or leakage. Repair any joints that show
signs of leakage in accordance with vent manufacturer’s instructions. Inspect igniter
When air is ducted to boiler, verify that air inlet hose is connected and
properly sealed. 1. Verify igniter operation — Look through blower
observation port (see Figure 74). Access the blower
Failure to inspect for the above conditions and have them by removing the boiler jacket front panel if not
repaired can result in severe personal injury or death. already removed.
Part number 550-142-056/0411 67


Inspect recuperator Figure 75 Blower motor
1. Follow the procedure on page 71 to inspect the recuperator and
clean if necessary.
Inspect temperature mixing system

1. Carefully check the temperature of the system return piping as
it passes through the boiler jacket and on the return pipe inside
the boiler jacket just before it enters the boiler sections. You may
do this with a surface pyrometer or by lightly touching the piping
with your fingers.
To avoid potential of severe burn — Do not rest hands
on or grasp pipes. Use a light touch only. Return piping
may heat up quickly.
2. The temperature of the water entering the system should quickly
heat up to about 140°F, being considerably hotter than the return
water from the system.
3. This is accomplished with the two internal boiler circulators.
The Bypass circulator (page 2, item 7) takes hot water from the
boiler supply outlet and blends it with return water. The System
circulator (page 2, item 6) slows down to aid in raising the return
temperature entering the sections.
4. If the temperature mixing system does not work correctly, check
the two circulators to be sure they are flowing water. If the circula-
tors are operating normally but the temperature mixing system Inspect blower motor
does not maintain water at the enterance to the boiler sections at
140°F, you may need to replace the boiler IBC or water temperature 1. See Figure 75. With boiler power off, place a few drops
sensor (page 2, items 1 and 8). of Anderol 465 in each of the two oil cups.
Use only Anderol 465 to lubricate the blower

Inspect limit controls and cutoffs motor. Do not use universal household oils.
Motor could be damaged, resulting in possible
1. Inspect and test the boiler limit control. Verify operation by turning
severe property damage.
control set point below boiler temperature. Boiler should cycle off.
Return dial to original setting.
2. Inspect and test additional limit controls or low water cutoffs Inspect oiled-bearing circulators
installed on system. Follow the device manufacturer's instructions.
1. Both of the circulators installed in the boiler are water-
lubricated. No oiling is required.
Inspect gauges
2. Check other circulators in the system. Oil any circula-
1. Boiler pressure/temperature gauge — Inspect gauge and check tors requiring oil, following circulator manufacturer’s
whether readings are reasonable. Replace if any signs of leakage from instructions. Over-oiling will damage the circulator.
case or improper readings.
2. System gauges (if installed) — Inspect and check readings of other
gauges in system.
68 Part number 550-142-056/0411


Figure 76 Relief valve
Inspect boiler relief valve
1. Inspect the relief valve (Figure 76) and lift the lever to verify
flow as in the following warnings, excerpted from a relief valve
manufacturer’s warning label. Before operating any relief valve,
ensure that it is piped with its discharge in a safe area to avoid
severe scald potential. Read page 12 before proceeding further.
Safety relief valves should be reinspected AT LEAST

ONCE EVERY THREE YEARS, by a licensed plumb-
ing contractor or authorized inspection agency, to
ensure that the product has not been affected by cor-
rosive water conditions and to ensure that the valve
and discharge line have not been altered or tampered
with illegally. Certain naturally occurring conditions
may corrode the valve or its components over time,
rendering the valve inoperative. Such conditions are
not detectable unless the valve and its components
are physically removed and inspected. This inspec-
tion must only be conducted by a plumbing con-
tractor or authorized inspection agency — not by To complete Annual Start-up,
the owner. Failure to reinspect the boiler relief valve perform startup and checks:
as directed could result in unsafe pressure buildup,
1. COMPLETE the annual start-up procedures
which can result in severe personal injury, death or beginning on page 66.
2. Start boiler and perform checks and tests speci-
fied in this manual.
Following installation, the valve lever must be
operated AT LEAST ONCE A YEAR to ensure that 3. Verify cold fill pressure is correct and that operat-
waterways are clear. Certain naturally occurring ing pressure does not go too high.
mineral deposits may adhere to the valve, rendering 4. Complete the check-out procedure on page 62.
it inoperative. When manually operating the lever,
water will discharge and precautions must be taken
to avoid contact with hot water and to avoid water
damage. Before operating lever, check to see that a Review with owner
discharge line is connected to this valve directing
the flow of hot water from the valve to a proper
1. Review the User’s Information Manual with the
place of disposal. Otherwise severe personal injury owner.
may result. If no water flows, valve is inoperative.
2. Emphasize the need to perform the maintenance
Shut down boiler until a new relief valve has been schedule specified in the User’s Information
installed. Manual (and in this manual as well).
3. Remind the owner of the need to call a licensed
2. After following the above warning directions, if the relief contractor should the boiler or system exhibit
valve weeps or will not seat properly, replace the relief valve. any unusual behavior.
Ensure that the reason for relief valve weeping is the valve and 4. Remind the owner to follow the proper shutdown
not over-pressurization of the system due to expansion tank procedure and to schedule an annual startup at
waterlogging or under-sizing. the beginning of the next heating season.
Part number 550-142-056/0411 69

Service & maintenance

Cleaning boiler heating surfaces Figure 77 Blower housing removal procedure
The service procedures in this manual
must only be performed by a qualified
boiler service technician. Failure to com-
ply could result in severe personal injury,
death or substantial property damage.
The boiler contains ceramic fiber and
fiberglass materials. Use care when han-
dling these materials per instructions
on page 103 of this manual. Failure to
comply could result in severe personal
injury.
1. If inspection of the boiler flueways indicates the presence
of soot, clean the boiler heating surfaces using the
following procedure. The process requires remov-
ing the blower housing to allow spraying water
through the boiler combustion chamber.
2. Before proceeding, obtain a GWC gasket replace-
ment kit, consisting of igniter, recuperator, flueway
inspection port and blower flange gaskets.
To remove the blower assembly

1. Turn off boiler by turning down the thermostat.
Then turn off power at the boiler service switch.
Close manual gas valve on incoming gas line to
boiler.
Turn off power and gas to the boiler.
Failure to do so can cause severe personal
damage.
Wait several minutes after boiler has
stopped to allow the igniter to cool to 1 Blower assembly 8 Gas/air orifice plate
avoid severe personal injury or death.
2 Blower support bracket 9 Red pressure switch hose
2. See Figure 77.
3 Blower motor wiring harness 10 White pressure switch hose
3. Disconnect: 4 Air pressure switch 11 Inlet air hose and clamps
a. Remove union outside of boiler
b. Gas tubing from gas valve outlet by removing 5 Blower flange gasket (replace this) 12 Gas tubing
the 4 screws securing the outlet fitting to the 6 Burner cone and ring assembly 13 Igniter
valve. (Save the o-ring in the fitting.) 7 Igniter gasket (replace this) 14 Gas valve and bracket
c. Remove gas valve and bracket
d. Hose from gas valve to gas/air manifold
e. Pressure switch hoses 6. Grasp blower housing and pull free from studs. Turn clockwise slightly,
f. Air inlet hose until blower assembly can be removed safely from inside of boiler jacket.
g. Blower motor wiring harness from IBC 7. Remove burner cone and gasket for inspection.
h. Igniter harness connected to igniter plug
i. Blower support bracket (remove screw secur- To clean heating surfaces
ing blower housing to bracket — on left side of
blower housing) 1. Remove the flueway inspection port cover (page 3, item g), if not al-
j. Ground wire. ready off of the boiler.
4. Remove the two igniter screws and washers. Care- 2. Place a catch pan under the inspection port to catch the cleaning
fully remove the igniter. Use care when handling — water.
igniter is very brittle. DO NOT touch igniter surface 3. Spray water into the boiler combustion chamber opening.
with hands or expose to any greasy substances. 4. Catch the runoff water in the pan below the inspection port.
5. Remove nuts from studs securing blower housing 5. Continue process until flueways are clean.
to front section.
70 Part number 550-142-056/0411

Service & maintenance (continued)

To clean the burner
Figure 78 Recuperator access and cleaning
The burner may contain ceramic fiber particles. Use
care when handling these materials per instructions on
page 103 of this manual. Failure to comply could result
in severe personal injury.
1. Clean the burner ports with a soft brush.
2. Use compressed air to blow out any particulate if necessary. Use
caution to avoid particulate being blown into the building.
To replace blower assembly

1. Place a new blower flange gasket over the studs at combustion
chamber opening.
2. Reinstall burner cone into chamber opening.
3. Position blower assembly over studs. Install nuts and tighten.
4. Install igniter and new igniter gasket. Fasten with screws and wash-
ers. Tighten only with hand-held screwdriver. DO NOT use electric
or pneumatic driver. Excessive torque will damage igniter. Do not
exceed 20 inch-pounds torque.
5. Connect:
a. Gas valve and piping (4 screws)
b. Gas tubing to gas valve outlet
c. Pressure switch hoses
d. Hose from gas valve to gas/air manifold Figure 79 Recuperator with access panel removed
e. Air inlet hose (GWC-070/105 top, GWC-140/175 bottom)
f. Blower motor wiring harness to IBC
g. Igniter harness to igniter plug
h. Blower support bracket (with screw)
i. Ground wire.
6. Be sure all wiring and hose connections are correct per Fig-
ure 77, page 70 and are secure on the hose barb fittings.
Inspecting and cleaning the recuperator

Turn off power and gas to the boiler. Failure to do so
can cause severe personal injury, death or substantial
property damage.
Wait several minutes after boiler has stopped to allow
the boiler components to cool to avoid severe personal
injury or death.
1. Remove the recuperator access panel and gasket (see Figure 78)
and inspect the interior with a flashlight.
2. If there are indications of debris or corrosion, disconnect the
condensate trap from the bottom of the recuperator and place a
catch pan underneath.
3. Flush the flueway (Figure 79, item 1) and tubes (Figure 79, item 2)
thoroughly with fresh water, allowing the water to drain out
through the recuperator condensate opening.
4. If all of the water doesn't drain from the flueway (Figure 79,
item 1), the drain holes (see Figure 80) may be plugged. Remove
the recuperator using the procedure under Removing/cleaning/
re-installing the recuperator, page 72.
Part number 550-142-056/0411 71

Service & maintenance (continued)

Removing/cleaning/re-installing the recuperator Figure 80 Recuperator flueway drain holes
Disconnect the vent pipe from the recuperator
1. The vent pipe must be disconnected (at the in-line flue drain, item
A in Figure 7, page 9).
2. If the vent piping can be moved enough, loosen the flue pipe clamp
on the in-line flue drain. Then lift the flue pipe up and move aside
slightly.
3. If the vent piping cannot be moved, then cut the flue pipe carefully
so a coupling can be inserted later, or remove a section of vent pipe
if using stainless vent pipe.
Isolate boiler and drain partially
1. Remove the jacket top panel and front panel.
2. Allow time for the boiler to cool down if it has been operating.
3. Close the isolation valves on the boiler supply and return con-
nections.
4. The boiler will have to be partially drained.
a. Place a large pan under the boiler drain valve.
b. Slowly open the drain valve and allow about a gallon of water
to drain out.
c. Place the pan under the water connection flanges on the re-
cuperator.
d. Loosen the upper recuperator flange and allow any water in Re-install the condensate trap and recuperator ac-
the line to run out. cess cover
e. Loosen the lower recuperator flange (return connection) and 1. Replace the condensate trap and recuperator access
allow the water in the line and recuperator to drain out. cover — tighten bolts securely (do not exceed 18 inch-
5. After the recuperator and water lines have been drained, disconnect pounds, 2 N-m, torque).
both recuperator flanges. If the recuperator shows signs of significant
Remove the recuperator corrosion or deterioration, contact Wil-
liamson-Thermoflo for recommendations
1. See Figure 98, page 93. Loosen the (4) nuts that secure the recu-
on investigating the cause and replacing the
perator to the boiler.
recuperator if necessary.
2. Carefully slide the recuperator off of the (4) studs.
3. Disconnect the plug-in connector on the thermal fuse (Fig- Make sure the recuperator access cover gasket
ure 98, page 93, item 27). is in good condition. Replace if necessary.
4. Loosen the flue adapter clamp and remove the in-line drain fitting Make sure the recuperator access cover and
from the flue adapter. the condensate trap are re-installed securely.
5. Dump any remaining water from the recuperator. Failure to comply with the above could result
6. Look through the flue adapter and locate the flueway drain holes in severe personal injury, death or substantial
as shown in Figure 80. property damage.
7. Use a brush or other means to remove blockage from these
holes. Re-connect the vent pipe
8. Rinse the recuperator thoroughly. 1. If the vent pipe was lifted out, re-insert the vent pipe
into.
Re-install the recuperator 2. If the vent pipe was cut, install a coupling in the vent
1. Inspect the recuperator gaskets to make sure all are in good condi- line to allow re-connection.
tion. Replace if there is any sign of damage. 3. If a section was removed (stainless vent pipe), replace
2. Attach the recuperator at the boiler connection. the section.
3. Secure with the four nuts. 4. Re-connect the vent pipe to the in-line drain fitting and
4. Re-connect the water connections to the upper and lower recu- tighten the clamp.
perator flanges. When replacing the vent pipe, follow all in-
5. Re-insert the in-line drain fitting into the recuperator vent adapter. structions in this manual to ensure the vent
Tighten the clamp to secure in place. is properly completed. Failure to properly the
6. Re-connect the plug-in connector on the thermal fuse (Fig- vent pipe could result in severe personal in-
ure 98, page 93, item 27). jury, death or substantial property damage.
72 Part number 550-142-056/0411

Troubleshooting
VERIFY PROPER OPERATION AFTER Figure 81 Connecting a manometer to check
SERVICING. air pressure switch. DO NOT use this
arrangement to check gas valve
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and danger-
ous operation.
Never jumper (bypass) any device except for momentary
testing as outlined in Troubleshooting charts. Severe
personal injury, death or substantial property damage
can result.
The IBC and boiler controls can malfunction if they get
wet. Never try to use a control that has been flooded or
wet. Replace it. Failure to comply can result in severe
The boiler contains ceramic fiber and fiberglass materials.
Use care when handling these materials per instructions
on page 103 of this manual. Failure to comply could
result in severe personal injury.
Before troubleshooting
1. Have a voltmeter that can check 120 VAC, 24 VAC, 24 VDC and
a continuity checker.
2. Check for 120 VAC (min. 102-max.132) to boiler.
3. Make sure thermostat is calling for heat and contacts (including
appropriate zone controls) are closed. Check for 24 VAC between
thermostat wire nuts and ground.
4. Have an inclined manometer with 0 – 2” w.c. range.
Check the following

1. Wire connectors to IBC are securely plugged in at IBC and origi-
nating control.
2. Hoses are properly and securely plugged in and are not dam-
aged.
6. If manometer reading is at least 1.0” w.c., but there is
not 24 VAC between both air pressure switch terminals
Checking the air pressure switch and ground, replace air pressure switch.
Do not use manometer as shown in Figure 81 to test gas Troubleshooting air pressure reading
valve outlet pressure. Where instructed in this manual
to check gas valve outlet pressure, follow instructions 1. If manometer reading is lower than 1.4” w.c. check for
carefully, particularly regarding connection of manom- possible causes:
eter. Manometer fluid will cause permanent damage to • Blockage in hoses.
gas valve. Severe personal injury, death or substantial
• Loose blower wheel on motor shaft.
property damage can result.
• Blower motor not at proper rpm.
Check switch pressure setting • Blockage in air inlet or hose.
1. See Figure 81. • Blockage in flue pipe or termination.
2. Remove both air pressure switch hoses from air pressure switch. • Condensate trap filled w/condensate.
3. Install tees and tubing as shown in Figure 81 to inclined manometer.
Return to normal operation
4. Turn off gas valve and set thermostat to call for heat. Blower will
run but burner will not ignite. 1. When pressure reading is proper and air pressure switch
5. Check for 24 VAC between both air pressure switch terminals and is operating properly, remove tees and reinstall hoses to
ground. air pressure switch.
Part number 550-142-056/0411 73

Troubleshooting (continued)
Igniter Figure 82 Igniter
Wait several minutes until igniter cools down before at-
tempting replacement. Failure to do so will cause severe
personal injury.
1. Disconnect igniter (Figure 82) from igniter wiring harness and
remove igniter before removing from blower assembly.
2. Replace igniter gasket if original gasket is frayed or damaged OR
if room-temperature resistance across igniter is not between 40
and 95 ohms.
3. Igniter is fragile — handle with care. Do not touch igniter surface Figure 83 Gas valve
with bare hands. Body oils can cause failure of the carbide.
Gas Valve
The gas valve (Figure 83) operates with a negative pres-
sure at the outlet — approximately –0.2” w.c. — DO
NOT set gas pressure higher than this.
Follow instructions in this manual carefully if testing
gas valve outlet pressure. Failure to comply can result in
severe personal injury or death.
The gas valve outlet is bolted to the gas line adapter and
Figure 84 Blower housing
sealed with an o-ring. When replacing valve, replace only
with valve listed in this manual for use with the GWC
boiler. Failure to comply could result in severe personal
Blower Housing
Do not disassemble blower housing (Figure 84). A
fire or explosion causing severe personal injury, death or
substantial property damage can result. If you suspect a
problem, replace blower housing. Follow instructions on
page 70 for blower housing removal and replacement.
Thermal fuse Figure 85 Thermal fuse

1. The thermal fuse (Figure 85) protects vent pipe from excess flue
temperatures.
2. If the thermal fuse opens, it must be replaced. See page 92 for
replacement information.
If the thermal fuse opens, investigate the cause before
replacing switch and starting the boiler. DO NOT attempt
to jumper the switch. Failure to comply could result in
severe personal injury, death or substantial property
damage.
Figure 86 Return temperature sensor
Return temperature sensor

1. See Figure 86.
2. Resistance check method:
a. With the boiler operating, use a contact thermometer to
measure the temperature of the return pipe next to the return
temperature sensor. Make a note of the temperature.
b. Turn the boiler ON/OFF switch off.
74 Part number 550-142-056/0411

c. Immediately disconnect the return temperature sensor plug from
the IBC. Figure 87 Return temperature sensor resistance
d. Measure the resistance of the sensor. Write down the result.
Temperature Resistance Temperature Resistance
e. Let the sensor cool to room temperature and measure the resistance °F Ohms °F Ohms
again. Write down the result.
f. Compare the sensor resistances at both temperatures to the closest 60 15300 140 2480
temperatures in Figure 87. 70 11900 160 1680
g. If the measured values are within 10% of the values listed, the sen-
80 9310 180 1160
sor is good. If not, replace the sensor. See Replacement parts for
the part number. 100 5840 200 810
3. Fixed resistor method 120 3760 212 674
a. With the boiler power OFF, disconnect the return temperature
sensor plug at the IBC.
b. Insert a 2500-ohm resistor into the IBC sensor plug. Figure 88 GWC Integrated Boiler Control (IBC)
c. Restart the boiler.
d. If the boiler operates with the resistor, but not with the sensor, try
replacing the sensor. See Replacement parts for the part number.
IBC (integrated boiler control)

Make sure ground wiring is installed per wiring diagram. Good grounding
is extremely important for proper operation.
Solder or water splatter between plugs and circuit board
can cause improper operation of IBC. Place a shield over the
boiler internal controls and components during installation.
Failure to comply could result in severe personal injury, death
or substantial property damage.
IBC indicator lights — lockout modes

• See Charts 1 through 8 in this section for detailed trouble-shooting
procedures.
• To reset control after a lockout, turn off power at the 120 VAC service
switch or turn down all thermostats. Wait 45 seconds. Then restore
power and call for heat. POWER and FLAME lights flashing
• After an over-temperature lockout (POWER and LIMIT lights flash- • Usually indicates control has had three unsuccessful
ing), the control will only reset after interruption of 120 VAC for 45 ignition attempts or sensed flame when it shouldn’t
seconds. (And temperature at return water temperature sensor must be there. Boiler may not be properly grounded.
be below 240°F.)
POWER light flashing alone IBC indicator lights —
• Usually indicates reversed polarity of 120 VAC power wires. non-lockout modes
POWER and TSTAT CIRC lights flashing TSTAT CIRC light flashing alone
• Usually indicates stray voltage on external thermostat circuit wires • Usually indicates return water temperature sensor
or return water temperature entering boiler sections has not reached detects water at boiler return pipe less than 40°F.
140°F within 20 minutes. Both internal circulators will run continuously,
even with no call for heat, until temperature rises.
POWER and LIMIT light flashing alternately
• Usually indicates that limit circuit failed to cut off boiler at high tem- LIMIT light flashing alone
perature — return water temperature sensor has sensed water over • Usually indicates an open or shorted return water
235°F. temperature sensor.
POWER and PRESS SWITCH lights flashing Troubleshooting the IBC
• Usually indicates pressure switch is closed when it should not be, or • See Figure 89, page 76 for location of harness plug
pressure switch failed to close within 5 minutes of blower starting. receptacles and plugs on the IBC.
Part number 550-142-056/0411 75

Figure 89 IBC harness plug receptacle and indicator light locations
76 Part number 550-142-056/0411

Figure 90 Common causes and possible corrections, part 1
Symptom Common Causes Possible Corrections
Rapid cycling — boiler Thermostat installed where drafts Locate thermostat on inner wall away from
turns on and off frequently or heat affect reading heat sources or cool drafts.
Heat anticipator in thermostat Adjust thermostat per manufacturer’s

adjusted incorrectly instructions.
Incorrect limit setting Set limit according to system needs.

Maximum setting is 200°F. Increase limit
setting to decrease cycling.
Insufficient water flow through Check all valves to and from boiler. Return
boiler to proper setting.
Confirm circulator size.
Frequent release of water Expansion tank sized too small Call qualified service technician to check
through relief valve expansion tank operation and size.
Flooded expansion tank Call qualified service technician to check

expansion tank operation.
Inoperative limit control Call qualified service technician to replace

limit control.
Need to frequently add Leaks in boiler or piping Have qualified service technician repair
makeup water leaks at once to avoid constant use of
makeup water. Makeup water can cause
mineral deposits which, in turn, can cause
boiler section failure. Do not use petroleum-
base stop-leak compounds.
Black water condition Oxygen corrosion due to leaks in Have qualified service technician repair at
boiler and piping once. Keep pH of water between 7.0 to 8.5.
Part number 550-142-056/0411 77

Figure 91 Common causes and possible corrections, part 2
Symptom Common Causes Possible Corrections
Popping or percolating Mineral deposits in sections due Call qualified service technician to de-
noise heard in boiler to constant use of makeup water lime boiler, if necessary. In some cases,
deposits will be too heavy to remove with
de-liming procedures.
Have qualified service technician repair

leaks to eliminate need for constant
makeup water.
Incorrect pH of boiler water Call qualified service technician to check

pH level and correct. pH should be
maintained between 7.0 to 8.5.
Insufficient water flow through Check all valves to and from boiler. Return
boiler to proper setting.
Confirm circulator size.
Metal flakes found in vent Contaminated combustion air Remove any contaminating products, see
outlet or recuperator — supply — See manual page 13. manual page 13.
flueway corrosion
Provide outside air for combustion. Have
qualified service technician pipe-up kit.
Condensation of combustion Have qualified service technician check

gases in boiler sections operation of mixing system. Repair/replace
if necessary.
Some radiators or Air in system Bleed air from system through air vents in
baseboard units do not radiators or baseboard units.
heat or are noisy
Low system pressure Fill to correct pressure.
Check for leaks in boiler or piping. Have

qualified service technician repair at once.
High limit set too low Adjust high limit to higher setting.
78 Part number 550-142-056/0411

CHART 1 Troubleshooting POWER light status
Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow
instructions could result in severe personal injury, death or substantial property damage.
Is POWER light off? • Make sure service switch or circuit breaker is on or fuses
are good.
No Yes
• Remove 120 VAC IN plug (Figure 89, page 76, Item 1) on
IBC.
• Using voltmeter, check across top and bottom pins
Is POWER light . . . of 120 VAC IN receptacle.
Flashing Flashing with On steady Does voltmeter indicate 120 VAC?
alone? another light? (NOT flashing)? No Yes
TSTAT CIRC CHART 2, Problem is with incoming

light flashing page 80 electricity. Have licensed
electrician repair circuit.
LIMIT CHART 3,
light flashing page 81
• Reconnect 120 VAC IN plug.
PRESS SWITCH CHART 4, CHART 6, • Remove 120 VAC transformer PRIMARY plug
light flashing page 82 page 84 (Figure 89, page 76, Item 2) on IBC.
• Using voltmeter, check across top and bottom pins of PRI-
MARY receptacle.
FLAME CHART 5, CHART 7,
light flashing page 83 page 85 Does voltmeter indicate 120 VAC?
No Yes
NO LIGHT IS
FLASHING, CHART 8,
but there is page 86
insufficient heat
Replace IBC.
Retest
• Usually indicates polarity on incoming 120 VAC power
line is wrong.
• TURN OFF POWER at service switch or breaker, then
reverse the HOT and NEUTRAL wires entering the boiler • Reinstall 120 VAC transformer PRIMARY plug.
in the J-box. • Remove 24 VAC transformer plug (Figure 89, page 76,
• Restore POWER at service switch or breaker. Item 7) on IBC.
Is POWER light flashing now? • Using voltmeter, check across pins of receptacle.
No Yes Does voltmeter indicate 24 VAC?
No Yes
Boiler should now operate Have system checked by a Replace transformer. Replace IBC.
normally. licensed electrician. Retest. Retest.
If problem persists, call your
local Williamson-Thermoflo
sales representative.
Part number 550-142-056/0411 79

CHART 2 TSTAT CIRC & POWER lights flashing
Is return water temperature sensor clamped • Attach sensor to pipe with clamp provided.
securely to the return pipe in the boiler? • Follow return temperature sensor checking procedure
Yes No on page 74. Replace sensor if necessary.
• Retest.
• Check for stray voltage on the incoming thermostat wires. under any condition, check and correct the external wiring. (This
Disconnect the two external wires connected to the boiler is a common problem when using 3-wire zone valves.)
thermostat wires. • Once the external thermostat circuit wiring is checked and
• Connect a voltmeter across the two incoming wires. Close each corrected if necessary, reconnect the external thermostat
thermostat, zone valve and relay in the external circuit one at a circuit wires to the boiler thermostat wires and allow the boiler
time and check the voltmeter reading across the wires. There to cycle.
should NEVER be a voltage reading. If a voltage does occur
Did you find and correct a voltage across the two external thermostat circuit wires?
Yes No
• Boiler should now operate per the normal sequence of op- Is boiler internal Bypass circulator operating?
eration (Figure 71, page 63) if wiring was corrected.
No Yes
• Remove CIRCULATORS plug (Figure 89, page 76, Item 4)

from plug receptacle of IBC.
• Check the boiler internal return pipe where it enters the
• Place voltmeter leads across the right-side 120 VAC N and boiler sections. The TSTAT CIRC and POWER lights
120 VAC H pins of the CIRCULATORS receptacle. will flash as long as the return water temperature is less
Does the voltmeter indicate 120 VAC? than 130 °F.
No Yes • Wait up to 20 minutes to give the boiler and system a
chance to respond.
Does problem persist?
• Replace IBC. • Test wire continuity of No Yes
• Retest. circulator wire harness.
Is harness ok?
No Yes • Boiler may now be operating normal-
• Replace circulator harness. ly. Verify against normal sequence of
operation (Figure 71, page 63).
• Retest.
• Reconnect circulator harness to IBC.

• If boiler appears not to be heating, troubleshoot boiler
• Attempt to get the circulator started by giving it a sharp rap per CHART 8, page 86. If problem cannot be resolved,
on the end of the circulator motor (to release a possibly replace water temperature sensor and retest. Then re-
locked impeller). place IBC (IBC) if sensor does not correct the problem.
• If the circulator begins to operate, allow it to operate for a • If boiler is heating, but the temperature at the return
few minutes to see if the problem clears. pipe does not increase above 130 °F, there may be an
• If problem persists, replace the Bypass circulator. incorrectly-piped external circulator forcing water through
the boiler. Check external piping and correct.
• Retest.
80 Part number 550-142-056/0411

CHART 3 LIMIT & POWER lights flashing
• This is a LOCKOUT condition. The return water temperature did not catch the over-temperature condition). This is probably
sensor has signaled a temperature higher than 240 °F, but the an indication of a failure of the boiler limit control and possibly
boiler limit circuit is closed (indicating that the limit control circuit the block temperature switch as well.
• TURN OFF POWER to boiler at 120 VAC service switch. • Remove a wire from one of the limit control spade connec-
• Remove CONTROL CIRCUIT plug from IBC receptacle (Fig- tors.
ure 89, page 76, Item 5). • Connect an ohmmeter across the left and right pins on the
center row of the limit circuit harness.
Does the ohmmeter indicate a shorted wire harness (zero ohms)?

Yes No
• Replace control wiring harness. • Reconnect CONTROL CIRCUIT plug to IBC.

• Retest. • Remove WATER TEMP SENSOR plug from IBC receptacle
(Figure 89, page 76, Item 6).
• Connect an ohmmeter across the plug pins to check the sen-
sor resistance.
• Replace water temp sensor. Does the ohmmeter indicate a shorted sensor (zero ohms)?
• Retest. Yes No
Is boiler hot?
Yes No
• Set limit control knob to its minimum setting. Replace wire to

• Close the external manual gas valve. limit control spade connector.
• Remove one wire from the limit control space • Set a thermostat to call for heat.
connector.
• Turn on power at 120 VAC service switch.
• Set a thermostat to call for heat. Then turn on
power to the boiler at the 120 VAC service switch. • IBC should cycle boiler on and begin heating.
• The boiler system circulator should come on and • The limit control should shut off the gas valve when the
the IBC should try to cycle the boiler. temperature at the boiler pressure/temperature gauge has
reached no more than about 20 °F higher than the limit
• Allow the boiler circulator to run to cool off boiler switch setting.
and system water.
Does limit control shut off gas correctly?
• After the boiler and system water have cooled,
turn off power at the 120 VAC service switch and Yes No
open the external manual gas valve.
• Replace limit control and

• Replace IBC.
block temperature switch.
• Retest.
• Retest.
Part number 550-142-056/0411 81

CHART 4 PRESS SWITCH & POWER lights flashing
• Reset boiler control by turning off power at service switch or • Thermostat should call for heat and appropriate zone valves
turning down thermostat for at least 45 seconds. open.
Does blower motor operate?

No Yes
Is blower wheel turning at speed of blower motor?

No Yes
• Remove BLOWER plug (Figure 89, page 76, Item 3) from

plug receptacle of IBC. • TURN OFF POWER at • Wait 5 minutes.
service switch.
• Place voltmeter leads across the 120 VAC N and 120 VAC H Is purge light flashing?
pins of the BLOWER receptacle. • Properly position blower
wheel on blower motor No Yes
Does the voltmeter indicate 120 VAC? shaft and tighten set screw.
(Or replace blower housing
No Yes assembly.)
• Retest.
• TURN OFF POWER at service switch.

Does blower wheel turn freely by hand? • Boiler should be in normal operating se-
quence (Figure 71, page 63).
No Yes • Observe operation until thermostat is satis-
fied and blower has completed its post-
purge cycle.
• Properly position blower
• Replace blower motor.
wheel on blower motor shaft
(Also check blower
and tighten set screw. (Or
housing assembly.
replace blower housing • Check condensate trap. at speed of blower motor?
Replace if necessary.) Is blower wheel turning
assembly.)
• Retest. Is there condensate present?
• Retest. No Yes
No Yes
• Remove one of the red wires connected to the pressure

switch.
Are vent or combustion air • Drain condensate.
• Check continuity across the switch terminals. passages blocked?
• Retest.
Does the ohmmeter indicate the switch is closed?
No Yes
No Yes
• Check air pressure switch per page 73.

• Replace IBC. • Clear passages and recycle boiler.
• Replace if necessary.
• Retest. • Recheck boiler operation.
• Retest.
82 Part number 550-142-056/0411

CHART 5 FLAME & POWER lights flashing
Are manual main shutoff valve and gas valve turned on?
No Yes
• Check gas valve harness wires and check for tight wiring connec-
• Open manual gas valve.`
tions on gas valve and IBC. Repair/replace as necessary.
• Restart boiler, following Operating instructions on boiler
• Recycle boiler by thermostat or service switch (holding power off for
(see Figure 72, page 64).
at least 45 seconds).
• Check for proper operation (per normal sequence of
• Thermostat should call for heat and appropriate zone valves close.
operation).
During step 5 of normal sequence of operation (Figure 71, page 63),
is there 24 VAC across gas valve terminals?
No Yes
• Replace IBC.
• Retest.
• Check and/or replace igniter.

• Recycle boiler by thermostat or service switch. Thermostat should
call for heat and appropriate zone valves close.
• Wait 5 minutes.
Are FLAME & POWER lights flashing?
No Yes
• Boiler should now operate normally.

• Original flashing FLAME light caused by igniter not
operating properly.
• See normal sequence of operation (Figure 71, page 63).
• Check and/or replace gas valve.
• Recycle boiler by thermostat or service switch. Thermostat should
call for heat and appropriate zone valves close.
• Wait 5 minutes.
Are FLAME & POWER lights flashing?
No Yes

• Original flashing FLAME light caused by gas valve not
operating properly.
• Call your local Williamson-
• See normal sequence of operation (Figure 71, page 63). Thermoflo sales representa-
tive.
Part number 550-142-056/0411 83

CHART 6 TSTAT CIRC light flashing and POWER light on steady
• This is NOT a lockout mode. sensor is less than 40 °F, both of the internal boiler circula-
tors will run continuously, even if there is no call for heat
• The IBC is signaling that the return water temperature sen-
(though the boiler will not fire until the thermostat calls for
sor is detecting a temperature less than 40 °F.
heat). This operation is intended to reduce chances of freez-
• While the temperature at the boiler return water temperature ing during system down times by keeping water flowing.
• Attach sensor to pipe with clamp Is return water temperature sensor clamped securely to the return pipe in the boiler?
provided.
No Yes
• If problem persists, replace return
water temperature sensor.
• Retest.
Are both boiler internal circulators operating?
No Yes
• Remove CIRCULATORS plug (Figure 89, page 76, Item 4)
from plug receptacle of IBC.
• Place voltmeter leads across the 120 VAC N
and 120 VAC H pins of the CIRCULATORS receptacle on
the side corresponding to the circulator not operating.
Does the voltmeter indicate 120 VAC? Is there a call for heat?
• Verify by removing thermostat wirings at boiler and check-
No Yes ing continuity across external wires.
No Yes
• Test wire continuity of

• Replace the IBC (IBC). • This is normal operation for • Wait 10 minutes to allow
circulator wire harness.
• Retest. water less than 40 °F at boiler heat from the boiler to
Is harness ok? internal return pipe. raise the water tempera-
No Yes • Condition should change after ture.
a call for heat, when the boiler Does LIMIT light quit flashing
will heat up the water. (and pipes begin to heat up)?
• Replace circulator harness.
• Retest. No Yes
• Boiler is not heating.

• Reconnect circulator harness to the IBC.
• Troubleshoot boiler using
• Attempt to get the circulator started by giving it a sharp rap on the CHART 8, page 86.
end of the circulator motor (to release a possibly locked impeller).
• If the circulator begins to operate, allow it to operate for a few
minutes to see if the problem clears.
• If problem persists, replace the bypass circulator.
• Verify correct sequence of operation (Figure 71, page 63).
• Retest.
84 Part number 550-142-056/0411

CHART 7 LIMIT light flashing and POWER light on steady
• This is NOT a lockout mode. The IBC should only be signal- • This situation is usually corrected by replacing the sensor,
ing that the water temperature sensor is either shorted or as described below.
there is an open circuit across the sensor terminals.
• Remove SENSOR plug from receptacle on IBC (Figure 89, page 76, Item 6).
• Then re-insert.
Does LIMIT light still flash?
No Yes
• Replace sensor and harness.

Does LIMIT light still flash?
No Yes
• Boiler may now be operating correctly. Verify per normal

sequence of operation (Figure 71, page 63).
• Replace IBC.
• Retest.
Part number 550-142-056/0411 85

CHART 8 Insufficient heat or no heat to system (POWER light on steady)
• Has it been at least 5 minutes since setting thermostat to Is boiler System circulator operating?
call for heat? If not, wait 5 minutes. Is system heating?
• Is thermostat set to call for heat? Remove thermostat No Yes
wires at boiler and check continuity across the two wires. If
circuit isn't closed, check external thermostat (zone valve,
relay, etc.) wiring. Correct problems and retry. • Remove system circulator harness plug from CIR-
CULATORS plug receptacle (long harness) (see
• Reconnect external thermostat wiring at boiler. Figure 89, page 76, Item 4). Check with voltmeter
Is thermostat circuit closed (continuity across wires)? across left-side 120 VAC N and 120 VAC H pins of
receptacle.
No Yes
Does voltmeter show 120 VAC across pins?
No Yes
Are all red lights off? • Boiler is in standby.
No Yes • Set thermostat to call for heat

and recheck operation. • Replace IBC. • Repair/replace circula-
• Retest. tor. Retest.
• Verify sequence of operation,
Figure 71, page 63. • Repair/replace wiring.
• Wait 30 seconds. Retest.
Are all red lights
off? • Check block switch on top of • Wait 5 minutes.
boiler with continuity checker. Is FLAME light on?
No Yes
Are contacts closed?
No Yes
No Yes
• Replace IBC.
• If you have sufficient heat — boiler should follow normal
• Retest.
operating sequence (Figure 71, page 63).
• Check across limit • If you have less than sufficient heat —
switch contacts with Is vent or combustion air piping free of blockage?
• Wait for cast iron continuity checker.
block to cool to room Are contacts closed? No Yes
temperature.
Are block switch Yes No • Correct conditions and • Contact your William-
contacts closed? recheck operation. See son-Thermoflo sales
sequence of operation, Fig- representative.
ure 71, page 63.
No Yes • Check across thermal fuse
leads with continuity checker.
• Wait for boiler water to cool to temperature 20 to 30 °F
Is circuit closed? lower than temperature set on limit switch.
• Replace Are limit switch contacts closed?
switch. No Yes
No Yes
• Retest.
• Replace
• Replace IBC. • Replace limit switch.
thermal fuse.
• Retest. • Retest.
• Retest.
• Excessive block temperature has been reduced to safe op- • Boiler water temperature exceeded setting on limit switch
erating level. Check for low water level or mineral deposits with thermostat calling for heat. Boiler is OK. (See se-
in sections. Correct before proceeding. quence of operation, Figure 71, page 63)
• Restart boiler and check sequence of operation (Fig- • Also check operation of setting on limit switch (should be
ure 71, page 63). above 140°F.).
86 Part number 550-142-056/0411

Replacement parts
Figure 92 Miscellaneous parts
Description Model Williamson-

Thermoflo
part number
Vent termination plate for 3" AL29-4C or 3" PVC pipes (plate includes knockouts to
All 452-100-163WT
provide larger holes needed for PVC)
Vent Termination Bird Screen 3" PVC (1 pc) All 383-500-105WT
Termination bag assembly (includes two 2-hole sidewall termination plates and two
All 542-200-314WT
bird screens, mounting screws and plastic anchors)
3" PVC Concentric Vent Kit All 383-500-350WT
Adapter 3-inch AL29-4C Vent Starter, FasNSeal All 560-907-717WT
Adapter 3-inch AL29-4C Vent Starter, Z-Vent All 560-907-723WT
Adapter 3-inch AL29-4C Vent Starter, Saf-T-Vent All 560-907-724WT
Contact Williamson-
Adapter 3-inch AL29-4C Vent Starter, CORR/GUARD All
Thermoflo
Chemicals:
Antifreeze, aluminum-safe, Sentinel X500 . . . . . . . . . . . . . . . . . . . . . . 592-900-004WT
Corrosion inhibitor, Sentinel X100 . . . . . . . . . . . . . . . . . . . . . . . . . . 592-900-002WT
(one tube is shipped with boiler) All
Sentinel X100 Inhibitor Test Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592-900-005WT
(one kit is shipped with boiler)
Cleaner, Sentinel X400 . . . . . . . . . . . . . . . . . . . . . . . . . . . 592-900-003WT
Condensate neutralizer kit All 383-500-631WT
Part number 550-142-056/0411 87

Replacement parts (continued)

Figure 93 Section assembly
Item Description Model Williamson-Thermoflo

number part number
1 Block assembly, includes: 070 322-200-304WT

Front section, intermediate section, back section, square 105 322-200-305WT
cut seals — 2”, silicone sealant, tie rods, tie rod nuts, tie rod 140 322-200-306WT
washers, blower flange gasket, igniter, igniter gasket, screws, 175 322-200-307WT
lock washers, studs, nuts
2 Front section replacement kit, includes front section, square All 382-200-713WT
cut seals (4), silicone sealant, blower flange gasket, igniter
gasket, studs (13), nuts (13)
3 Intermediate section (also required Section replacement kit) All 312-200-110WT
4 Back section (also required Section replacement kit) All 312-200-130WT
Not Section replacement kit All 382-200-305WT

shown
5 Tie rods 070 560-234-499WT

105 560-234-525WT
140 560-234-503WT
175 560-234-504WT
6 Base rail legs — (2) per boiler 070 and 105 452-100-173WT
140 and 175 452-100-174WT
7 Base rail brace — (2) per boiler All 452-100-080WT
8 Blower housing support All 452-100-111WT
9 Block temperature limit switch All 382-200-375WT
10 Inspection port cover All In Insp. port kit
11 Inspection port gasket All 590-317-628WT
— Inspection port kit (includes cover and gasket) All 542-200-181WT
12 Recuperator connection gasket All 590-317-629WT
13 Stud, B\zn” – 18 x 1¼” All 560-340-581WT
14 Hex nuts (4 each), B\zn” / lock washers (4 each), B\zn” All Obtain locally
88 Part number 550-142-056/0411


Figure 94 Section assembly
Part number 550-142-056/0411 89


Figure 95 Jacket assembly

number part number
1 Jacket panel, top 070 and 105 382-200-700WT

140 and 175 382-200-701WT
2 Jacket panel, front All 382-200-702WT
3 Jacket panel, left side, front 070 and 105 382-200-703WT

140 and 175 382-200-704WT
4 Jacket panel, left side, rear 070 and 105 382-200-705WT

140 and 175 382-200-706WT
5 Jacket panel, right side 070 and 105 382-200-724WT

140 and 175 382-200-725WT
6 Jacket panel, rear All 382-200-726WT
7 Jacket brace All 422-200-179WT
8 Jacket panel, interior All 382-200-727WT
9 Base rail assembly All see Figure 93, page 88

items 6 and 7
10 Screw, sheet metal type AB, serrated hex washer head All —
Phillips #10 x C\,” steel black phosphate
90 Part number 550-142-056/0411


Figure 96 Jacket assembly
Part number 550-142-056/0411 91


Figure 97 Blower assembly
number part number
1 Burner replacement kit, includes burner, blower flange gasket, igniter, 070 382-200-320WT
igniter screws, igniter washers, igniter gasket 105 382-200-325WT
140 382-200-330WT
175 382-200-335WT
2 Blower flange gasket All 590-317-610WT
3 Air pressure switch (0 to 5,500 feet elevation) All 382-200-723WT
— Air pressure switch (5,500 to 10,000 feet elevation) All Consult W-T factory
4 Blower motor replacement kit, includes blower motor, motor mounting All 382-200-345WT
grommets, screws, lock nuts and 9" Allen wrench
5 Blower housing assembly replacement kit, includes: blower housing, All 382-200-340WT
obsv. port, blower housing cover plate, blower motor mounting brackets,
washer hold down bracket, lock nuts, motor mount grommets, blower
motor, blower wheel, magnetic washer, silicone sealant, screws, blower
flange gasket, igniter, igniter washers, igniter screws, igniter gasket
6 Conversion kit, natural to propane, includes . . . . . . . . . . . . . . . . . . . . . . 070 510-811-926WT
Propane orifice plate, label 105 510-811-927WT
140 510-811-928WT
175 510-811-929WT
Orifice plate, natural gas . . . . . . . . . . . . . . . . . . . . . . 070 510-811-934WT
105 510-811-935WT
140 510-811-936WT
175 510-811-937WT
7 Gas/air manifold assembly, includes gas/air manifold, gas tubing, All 382-200-362WT
washers, screws, gas valve o-ring
8 Sense line condensate trap, includes sense line condensate trap and All 382-200-409WT
hoses
10 Gas valve kit, complete, includes gas valve, gas cock, 1/2" nipple, bracket, All 382-200-411WT
o-ring, screws
12 Igniter replacement kit, includes igniter and gasket All 511-330-148WT
13 Igniter gasket All 590-317-599WT
14 Inlet air tube w/grill All 382-200-310WT
15 Hose clamp, 3” All 591-850-068WT
16 Inlet air hose, 3" by 19" long All 562-302-573WT
17 & 18 Inspection port cover and Inspection port gasket All see Figure 93, page 88
items 10 and 11
19 Recuperator connection gasket All see item 24
20 Condensate drain hose clamp All —
21 Condensate trap All 560-907-716WT
22 ½” PVC condensate tee All —
23 Condensate tee U-clamp All —
24 Recuperator kit, includes recuperator, recuperator connection gasket, 070 and 105 382-200-714WT
diamond flange gasket (2), connection hardware (4-nuts), flue gas 140 and 175 382-200-715WT
thermal fuse
25 Diamond flange, 1” npt All see item 24
26 Diamond flange gasket All 590-317-535WT
27 Flue gas thermal fuse All 511-724-295WT
28 In-line flue adapter with drain kit, includes in-line flue adapter with drain All 382-200-716WT
and
drain hose (6 inches)
29 Flue drain hose kit, 6 inches All 382-200-717WT
30 Recuperator cover plate 070 and 105 593-000-002WT
140 and 175 593-000-003WT
31 Recuperator cover plate gasket 070 and 105 593-000-004WT
140 and 175 593-000-005WT
32 Recuperator vent pipe seal All 593-000-006WT
92 Part number 550-142-056/0411


Figure 98 Blower assembly
Part number 550-142-056/0411 93


Figure 99 Trim assembly
Item Description Williamson-

number Thermoflo
part number
1 System circulator, Taco 007 511-405-113WT
2 Bypass circulator, Taco 007 511-405-113WT
3 Circulator gasket, Taco 110-339 590-317-543WT
Manifold, casting/circulator kit, includes water manifold, circulator gasket (Taco

4 382-200-720WT
110-339) (2), square cut seal (manifold to casting)
Return manifold, recuperator/circulator kit, includes water manifold, circulator

5 382-200-721WT
gasket (Taco 110-339) (1), diamond gasket
6 Square cut seal gaskets, casting, 2.31" 572-800-011WT
7 Diamond flange gasket 590-317-535WT
Supply manifold kit, includes water manifold, circulator gasket (Taco 110-339) (1),
8 382-200-722WT
square cut seal (manifold to casting)
9 Coin-operated air vent, 1/8” NPT 570-148-565WT
10 Wiring harness, circulators to IBC 591-391-824WT
11 Return water temperature sensor and clip 511-330-089WT
12 Tee, 1” x 1” x ¾” Obtain locally
13 Bushing ¾” x ¼” Obtain locally
14 Temperature and Pressure Gauge, 1/4" NPT 380-000-000
15 30 PSIG Relief Valve 511-546-920WT
16 Nipple, NPT — ¾” x 3” Obtain locally
17 Block temperature limit switch 382-200-375WT
18 Limit control without well, 200 °F maximum setpoint 382-200-719WT
19 Limit control well, ½” NPT 592-300-017WT
20 Drain valve, ¾” NPT 511-546-392WT
94 Part number 550-142-056/0411


Figure 100 Trim assembly
Part number 550-142-056/0411 95


Figure 101 Interior panel
Item Description Williamson-Thermoflo

number part number
1 Interior panel see Figure 95, page 90,

item 8
2 Integrated boiler control assembly, includes IBC and screws 382-200-448WT
3 Transformer 511-842-370WT
4 Air pressure switch see Figure 97, page 92

item 3
5 Wiring harness, IBC to junction box (not shown) 591-391-963WT
6 Wiring harness, IBC to hot surface ignitor (not shown) 591-391-819WT
7 Wiring harness, IBC to system and bypass circulators (not shown) 591-391-824WT
8 Wiring harness, IBC to controls (not shown) 591-391-964WT
96 Part number 550-142-056/0411


Figure 102 Interior panel
Part number 550-142-056/0411 97

Dimensions and ratings

Figure 103 Dimension drawing (see Figure 104, page 99 for dimensional table)
Item Description
number
1 1” NPT Supply
2 1” NPT Return
3 Combination pressure-temperature gauge, 2 ½” short shank
4 ¾” NPT Relief valve outlet
5 Plug dome, 2” black
6 Junction box
7 Inlet air fitting, 3" PVC
8 Flue outlet, 3" PVC
9 ½” Condensate drain
10 ½” NPT Gas supply connection (provided by others)
11 Drip leg (provided by others)
12 Union (provided by others)
13 Manual main shutoff gas valve (provided by others)
14 ON/OFF switch
98 Part number 550-142-056/0411

Dimensions and ratings (continued)

Figure 104 Boiler dimensional and physical data (see Figure 103, page 98)
Supply Return Length Gas Electrical Boiler Approx.

Boiler
connection service water shipping
model
L size (Note 1) required content weight
(includes
the internal
circulators)
(inches NPT (inches NPT (inches) (inches NPT (amperes) (gallons) (pounds)
male) female) female)
GWC-070 1 1 30¾ ½ 15 3.8 313

GWC-105 1 1 30¾ ½ 15 4.7 353
GWC-140 1 1 37¾ ½ 15 6.0 423
GWC-175 1 1 37¾ ½ 15 6.9 464
Note 1: Gas piping from meter to boiler to be sized per local utility requirements.
Figure 105 Boiler ratings
DOE
Boiler CSA DOE Net I=B=R AFUE Vent/ Boiler % Input derate vs vent length
model Input Heating water (Note 1) combustion water (Values shown are at maximum vent/air pipe length)
capacity rating air diameter content (Note 3)
(Note 1) (Note 2)
Direct Exhaust Venting Direct Vent Venting
MBH MBH MBH % Inches Gallons Natural gas Propane Natural gas Propane
GWC-070 70 65 56 91.9 3" PVC 3.8 up to 0.7% up to 1.4% up to 1.5% up to 2.8%
Notes: 1. Based on standard test procedures prescribed by the United States Department of Energy. Ratings also
referred to as CSA Output. NOTE that only DOE Heating Capacity and AFUE are certified by AHRI. AFUE is
also know as Annual Fuel Utilization Efficiency or Seasonal Efficiency.
2. Net I=B=R ratings are based on net installed radiation of sufficient quantity for the requirements of the building
and nothing need be added for normal piping and pickup. Ratings are based on a piping and pickup allowance
of 1.15 and are determined under the provisions governing forced draft boiler-burner units. An additional
allowance should be made for unusual piping and pickup loads.
3. All of the boilers will automatically de-rate as vent length increases, due to the pressure loss through the vent.
For vent/air pipe lengths less than the maximum, the derate equals the value above times vent length ÷ 100.
4. Boilers are tested for 50 PSIG working pressure.
5. GWC boilers are not available for millivolt systems.
Part number 550-142-056/0411 99


Figure 106 Multiple GWC boilers — ratings and engineering data — maintain the clearances shown on pages 6 and 7 —
see Figure 28, page 23 and Figure 29, page 23 for layout options
Total Manifolded
DOE Heating Boiler Net water
CSA combustion air
Boilers in system capacity H.P. ratings
input duct size
Model GWC
Input, Output, Square
- MBH
MBH MBH inches
Note 3
070 105 140 175 - Note 1 - Note 2
Figure 37, page 31
2 140 130 3.9 112 70

2 210 194 5.8 168 105
2 280 260 7.8 226 140
2 350 322 9.6 280 175
3 210 195 5.8 168 105
3 315 291 8.7 252 158
3 420 390 11.7 339 210
3 525 483 14.4 420 263
4 280 260 7.8 224 140
4 420 388 11.6 336 210
4 560 520 15.5 452 280
4 700 644 19.2 560 350
5 350 325 9.7 280 175
5 525 485 14.5 420 263
5 700 650 19.4 565 350
5 875 805 24 700 438
6 420 390 11.7 336 210
6 630 582 17.4 504 315
6 840 780 23.3 678 420
6 1050 966 28.9 840 525
7 490 455 13.6 392 245
7 735 679 20.3 588 368
7 980 910 27.2 791 490
7 1225 1127 33.7 980 613
8 560 520 15.5 448 280
8 840 776 23.2 672 420
8 1120 1040 31.1 904 560
8 1400 1288 38.5 1120 700
Note 1 Based on standard test procedures outlined by DOE for individual boilers.
Net I=B=R ratings are based on piping and pickup allowance of 1.15.
Note 2
Consult Williamson-Thermoflo for other allowances.
All GWC installations require a separate vent pipe and termination for each boiler. Vent piping cannot be manifolded. Install and
Note 3 terminate vents as described in vent/air installation instructions in this manual.
Combustion air piping can be individually piped or manifolded. See Figure 37, page 31, for manifolded air piping.
100 Part number 550-142-056/0411


Figure 107 Engineering data — see page 99 for additional technical information
Water flow rate per boiler Vent/air pipe size —

Boiler Provide a separate vent
Model for each boiler
GPM @ 20°F rise GPM @ 40°F rise
Note 1
GWC-070 6.5 3.3 3”
GWC-105 9.7 4.9 3”
GWC-140 13.0 6.5 3”
GWC-175 16.1 8.1 3”
All GWC installations require a separate vent pipe and termination for each boiler. Vent piping cannot be manifolded.
Note 1 Install and terminate vents as described in vent/air installation instructions in this manual.
Combustion air piping can be individually piped or manifolded. See Figure 37, page 31, for manifolded air piping.
Part number 550-142-056/0411 101

NOTES
102 Part number 550-142-056/0411

Handling ceramic fiber and fiberglass materials
HANDLING CERAMIC FIBER REMOVAL OR INSTALLATION

MATERIALS OF FIBERGLASS WOOL
Ceramic fibers can be converted to cristobalite This product contains fiberglass jacket insula-
in very high temperature applications. The
tion and ceramic fiber materials in combus-
International Agency for Research on Cancer
(IARC) has concluded, “Crystalline silica tion chamber lining or base panels in gas fired
inhaled in the form of quartz or cristobalite products. Airborne fibers from these materials
from occupational sources is carcinogenic to have been listed by the State of California as a
humans (Group 1).”: possible cause of cancer through inhalation.
❏❏ Avoid breathing dust and contact with skin and eyes. ❏❏ Avoid breathing dust and contact with skin and eyes.
• Use NIOSH certified dust respirator (N95). This type • Use NIOSH certified dust respirator (N95). This type
of respirator is based on the OSHA requirements for
cristobalite at the time this document was written. of respirator is based on the OSHA requirements for
Other types of respirators may be needed depending fiberglass wool at the time this document was written.
on the job site conditions. Current NIOSH recom- Other types of respirators may be needed depending
mendations can be found on the NIOSH web site at on the job site conditions. Current NIOSH recom-
http://www.cdc.gov/niosh/homepage.html. NIOSH mendations can be found on the NIOSH web site at
approved respirators, manufacturers, and phone http://www.cdc.gov/niosh/homepage.html. NIOSH
numbers are also listed on this web site.
approved respirators, manufacturers, and phone
• Wear long-sleeved, loose fitting clothing, gloves, and numbers are also listed on this web site.
eye protection.
• Wear long-sleeved, loose fitting clothing, gloves, and
❏❏ Apply enough water to the combustion chamber lining eye protection.
or base insulation to prevent airborne dust.
❏❏ Operations such as sawing, blowing, tear out, and spray-
❏❏ Remove combustion chamber lining or base insula- ing may generate airborne fiber concentration requiring
tion from the boiler and place it in a plastic bag for additional protection.
disposal.
❏❏ Wash potentially contaminated clothes separately from
❏❏ Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.
other clothing. Rinse clothes washer thoroughly.
NIOSH stated First Aid NIOSH stated First Aid
❏❏ Eye: Irrigate immediately ❏❏ Eye: Irrigate immediately
❏❏ Breathing: Fresh air ❏❏ Breathing: Fresh air
Part number 550-142-056/0411 103

Installation and service certificate

Boiler model __________________ Series __________ CP number ___________ Date installed _______________
 Installation instructions have been followed.

Measured Btuh input ____________  Check-out sequence has been performed.
 Above information is certified to be correct.
 Information received and left with owner/maintenance person.
Installer ________________________ ________________________________ ______________________________

(company) (address) (phone)
_______________________________
(installer’s signature)
W-T
8201 W. Calumet Rd.
Milwaukee, WI 53223
Part number 550-142-056/0411

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Model

This manual must only be used by a qualified

Part number 550-142-056/0411

3 Blower f Pressure/temperature gauge

8 Air pressure switch

2 Part number 550-142-056/0411

GWC Water Boiler

Part number 550-142-056/0411 3

4 Part number 550-142-056/0411

Please read before proceeding

Part number 550-142-056/0411 5

Prepare boiler location

High altitude installations

6 Part number 550-142-056/0411

Prepare boiler location (continued)

Figure 3 Minimum foundation dimensions (inches)

Part number 550-142-056/0411 7

Prepare the boiler (continued)

Orifice plate installation, when required

Boiler model Natural gas marking Propane marking

To replace the plate, using a manual screwdriver or nut driver, see

8 Part number 550-142-056/0411

Prepare the boiler (continued)

Part number 550-142-056/0411 9

Prepare the boiler (continued)

Rotate the boiler into position

10 Part number 550-142-056/0411

Prepare the boiler (continued)

Prepare boiler for test — see Figure 10

Fill and pressure test

Part number 550-142-056/0411 11

Install water piping

General piping information Figure 12 Install and pipe relief valve

Minimum pipe size for boiler loop piping

Figure 11 Provide boiler loop piping no smaller than listed

Boiler loop pipe size, Minimum

Additional limit controls

Low water cut-off, when required

12 Part number 550-142-056/0411

Install water piping (continued)

Part number 550-142-056/0411 13

Install water piping (continued)

Pipe diaphragm- or bladder-type expansion tanks to the bot-

14 Part number 550-142-056/0411

Install water piping (continued)

The following simplified method for pipe and cir- ¾ 4 2 45

Part number 550-142-056/0411 15

Install water piping (continued)

Baseboard system piping —

16 Part number 550-142-056/0411

Install water piping (continued)

1 Isolation valves 4 Zone valve

Pipe sizes (NPT), minimum

GWC-140 1¼" ¾"

One-pipe diverter tees systems — The ap-

Part number 550-142-056/0411 17

Install water piping (continued)

Zoning with zone valves — Provide a separate 24-volt GWC-070/105 1”