American Standard TGBWF090A93AVA User manual

IMPORTANT — This Document is customer property and is to remain with this unit. Please
return to service information pack upon completion of work.
© 2007 American Standard Inc. All Rights Reserved
Natural Draft, Gas Fired Water Boiler with
Electronic Ignition and Cast Iron Heat
Exchanger
INSTALLATION GUIDE
*GBWF090A93AVA
*GBWF130A94AVA
*GBWF173A95AVA
*GBWF215A96AVA
*May be “A” or “T”
ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES
18-CG01D1-4
CUS
®

18-CG01D1-4
2
1.0 Safety Considerations
IMPORTANT: Read this entire manual before
beginning installation procedures.
Read this manual carefully before attempting to
install, operate, or perform maintenance on this
boiler. Installation, service, and maintenance should
be performed by qualified technicians only.
NOTE: “Warnings” and “Cautions” appear at appro-
priate places in this manual. Read these carefully.
Your personal safety and the proper operation of
this heating product require that you follow them
carefully. The manufacturer assumes no liability for
installations or services performed by an indepen-
dent dealers.
Safety signal words are used to designate a degree
or level of seriousness associated with a particular
hazard. The signal words for safety markings are
WARNING and CAUTION.
▲
▲
WARNING
!
WARNING indicates a potentially hazardous situa-
tion which, if not avoided, could result in pro-
perty damage, death or serious injury.
▲
▲
CAUTION
!
CAUTION indicates a potentially hazardous situa-
tion which, if not avoided, may result in minor or
moderate injury. It is also used to alert against
unsafe practices and hazards involving only
property damage.
|
1.1 WARNINGS
▲
▲
WARNING
!
THE INFORMATION IN THIS GUIDE IS FOR USE
BY INDIVIDUALS HAVING ADEQUATE ELECTRI-
CAL AND MECHANICAL BACKGROUND NECES-
SARY TO INSTALL BOILER PRODUCTS. ANY
ATTEMPTS, BY UNQUALIFIED PERSONS, AT
PLUMBING, INSTALLING OR REPAIRING A
BOILER MAY RESULT IN PERSONAL INJURY
AND/OR PROPERTY DAMAGE. THE MANUFAC-
TURER OR SELLER CANNOT BE RESPONSIBLE
FOR THE INTERPRETATION OF THIS INFORMA-
TION, NOR CAN IT ASSUME ANY LIABILITY IN
CONNECTION WITH ITS USE.
▲
▲
WARNING
!
ELECTRICAL HAZARD
DISCONNECT POWER BEFORE INSTALLING
OR SERVICING THE BOILER. FAILURE TO
FOLLOW THIS WARNING COULD RESULT
IN SERIOUS INJURY, DEATH, OR PROPERTY
DAMAGE
▲
▲
WARNING
!
FIRE OR EXPLOSION HAZARD.
TURN OFF MAIN GAS VALVE BEFORE INSTAL-
LING, PERFORMING MAINTENANCE OR SERVI-
CING A BOILER.
FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY, DEATH, OR PRO-
PERTY DAMAGE
▲
▲
WARNING
!
EXPLOSION HAZARD
PROPANE GAS IS HEAVIER THAN AIR AND MAY
COLLECT IN ANY LOW AREAS OR CONFINED
SPACES. IF THE GAS BOILER IS INSTALLED IN
A BASEMENT, AN EXCAVATED AREA OR A CON-
FINED SPACE, IT IS STRONGLY RECOMMENDED
TO CONTACT A GAS SUPPLIER TO INSTALL A
GAS DETECTING WARNING DEVICE IN CASE OF
A GAS LEAK.
FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY, DEATH, OR PRO-
PERTY DAMAGE
NOTE: The manufacturer of your boiler does not test
any detectors and makes no representations regar-
ding any brand or type of detector.
▲
▲
WARNING
!
EXPLOSION HAZARD
ODORANT FADE MAY MAKE THE GAS UNDE-
TECTABLE EXCEPT WITH A WARNING DEVICE.
IF THE GAS BOILER IS INSTALLED IN A BASE-
MENT, AN EXCAVATED AREA OR A CONFINED
SPACE, IT IS STRONGLY RECOMMENDED TO
CONTACT A GAS SUPPLIER TO INSTALL A GAS
DETECTING WARNING DEVICE IN CASE OF A
GAS LEAK.
FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY, DEATH, OR PROP-
ERTY DAMAGE.
NOTE: The manufacturer of your boiler does not test
any detectors and makes no representations regar-
ding any brand or type of detector.
▲
▲
WARNING
!
FIRE HAZARD
DO NOT INSTALL THIS BOILER WHERE COMBU-
STIBLE PRODUCTS AND FLAMMABLE LIQUIDS
ARE STORED OR WHERE FLAMMABLE VAPORS
ARE PRESENT.
FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY, DEATH, OR PRO-
PERTY DAMAGE

18-CG01D1-4
3
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each
appliance connected to the venting system being
placed into operation could result in carbon monoxide
poisoning or death.
The following steps shall be followed for each appliance
connected to the venting system being placed into
operation, while all other appliances connected to the
venting system are not in operation:
1. Seal any unused openings in the venting system.
2. Inspect the venting system for proper size and
horizontal pitch, as required in the National Fuel Gas
Code, ANSI Z223.1/NFPA 54 or the CAN/CGA B149
Installation Codes and these instructions. Determine
that there is no blockage or restriction, leakage,
corrosion and other deficiencies which could cause an
unsafe condition.
3. As far as practical, close all building doors and
windows and all doors between the space in which the
appliance(s) connected to the venting system are
located and other spaces of the building.
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliance not
connected to the venting system. Turn on any exhaust
fans, such as range hoods and bathroom exhausts, so
they are operating at maximum speed. Do not operate
a summer exhaust fan.
6. Follow the lighting instructions. Place the appliance
being inspected into operation. Adjust the thermostat
so appliance is operating continuously.
7. If improper venting is observed during any of the above
tests, the venting system must be corrected in
accordance with the National Fuel Gas Code,
ANSI Z221.1/NFPA 54 and/or CAN/CGA B149
Installation Codes.
8. After it has been determined that each appliance
connected to the venting system properly vents where
tested as outlined above, return doors, windows,
exhaust fans, fireplace dampers and any other gas-fired
burning appliance to their previous conditions of use.
▲WARNING
!
The following warning complies with State of California law, Proposition 65.
HAZARDOUS GASES!
EXPOSURE TO FUEL SUBSTANCES OR BY-PRODUCTS
OF INCOMPLETE FUEL COMBUSTION IS BELIEVED BY
THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH
DEFECTS, OR OTHER REPRODUCTIVE HARM.
▲
WARNING
!
▲
▲
WARNING
!
CARBON MONOXIDE POISONING HAZARD
FAILURE TO FOLLOW THE STEPS OUTLINED
BELOW FOR EACH APPLIANCE CONNECTED
TO THE VENTING SYSTEM BEING PLACED
INTO OPERATION COULD RESULT IN CARBON
MONOXIDE POISONING OR DEATH.
▲
▲
WARNING
!
SAFETY WARNING
DO NOT BYPASS SAFETY CONTROLS
FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY, DEATH, OR PRO-
PERTY DAMAGE
▲
▲
WARNING
!
BURN HAZARD
ALLOW BOILER TO COOL DOWN PRIOR TO
SERVICING OR PERFORMING MAINTENANCE.
FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY, DEATH, OR PRO-
PERTY DAMAGE
▲
▲
WARNING
!
FIRE HAZARD
DO NOT INSTALL THIS BOILER DIRECTLY ON
CARPETING. FAILURE TO FOLLOW THIS WAR-
NING CAN RESULT IN PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
NOTE: THIS PRODUCT IS APPROVED FOR
INSTALLATION ON COMBUSTABLE FLOORING
MATERIALS EXCEPT FOR CARPET.
▲WARNING
!
SAFETY HAZARD
THESE BOILERS ARE NOT APPROVED OR
INTENDED FOR INSTALLATION IN MANUFAC-
TURED (MOBILE) HOUSING, TRAILERS, OR
RECREATIONAL VEHICLES.
FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY, DEATH, OR PROP-
ERTY DAMAGE
▲
▲
WARNING
!
DO NOT USE THIS UNIT IF ANY PART HAS BEEN
UNDER WATER. IMMEDIATELY CALL A QUALI-
FIED SERVICE TECHNICIAN TO INSPECT THE
BOILER AND TO REPLACE ANY PART OF THE
CONTROL SYSTEM AND ANY GAS CONTROL
WHICH HAS BEEN UNDER WATER.
FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY, DEATH, OR PRO-
PERTY DAMAGE
▲
▲
WARNING
!
HEAVY OBJECT HAZARD
A BOILER IS A HEAVY OBJECT. DO NOT
HANDLE OR WORK UNDER A BOILER WITHOUT
PROPERLY SECURING IT THROUGH SHORING,
BLOCKING OR CRIBBING. FOLLOW ALL STATE
AND FEDERAL CODES AND OSHA REGULA-
TIONS AND GUIDELINES FOR HANDLING THE
BOILER DURING INSTALLATION AND SERVI-
CING.
FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY, DEATH, OR PROP-
ERTY DAMAGE

18-CG01D1-4
4
▲
WARNING
!
The following warning complies with State of California law, Proposition 65.
This product contains fiberglass wool insulation!
Fiberglass dust and ceramic fibers are believed by the
State of California to cause cancer through inhalation.
Glasswool fibers may also cause respiratory, skin, or
eye irritation.
PRECAUTIONARY MEASURES
●Avoid breathing fiberglass dust.
●Use a NIOSH approved dust/mist respirator.
●Avoid contact with the skin or eyes. Wear long-sleeved,
loose-fitting clothing, gloves, and eye protection.
●Wash clothes separately from other clothing: rinse
washer thoroughly.
●Operations such as sawing, blowing, tear-out, and
spraying may generate fiber concentrations requiring
additional respiratory protection. Use the appropriate
NIOSH approved respirator in these situations.
FIRST AID MEASURES
Eye Contact – Flush eyes with water to remove dust.
If symptoms persist, seek medical
attention.
Skin Contact – Wash affected areas gently with soap
and warm water after handling.
▲
▲
WARNING
!
If the information in this manual is not followed exactly,
a fire or explosion may result causing property
damage, personal injury or loss of life.
— Do not store or use gasoline or other flammable
vapors or liquids in the vicinity of this or any
other appliance.
— WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch;
do not use any phone in your building.
• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier,
call the fire department.
— DO NOT RELY ON SMELL ALONE TO DETECT
LEAKS. DUE TO VARIOUS FACTORS, YOU MAY
NOT BE ABLE TO SMELL FUEL GASES.
• U.L. recognized fuel gas and CO detectors are
recommended in all applications, and their
installation should be in accordance with the
manufacturer's recommendations and/or local
laws, rules, regulations, or customs.
— Installation and service must be performed by a
qualified installer, service agency or the gas
supplier.
1.2 CAUTIONS
▲
▲
CAUTION
!
Do NOT install the boiler in a corrosive or contamina-
ted atmosphere.
The following notes must be followed during the instal-
lation, servicing, and operation of this boiler:
1. NOTE: This device must only be used for the
purpose for which it is specially designed. This unit is
designed to heat water to a temperature below boiling
point at atmospheric pressure and must be connected
to a hydronic heating system and/or a water supply
system for domestic use, compatible with its perfor-
mance, characteristics and its heating capacity. Any
other use is considered improper.
2. NOTE: These instructions do not cover all varia-
tions in systems or provide for every possible con-
tingency. Should further information be desired or
particular problems arise which are not covered suffi-
ciently by this manual, contact your local distributor
for assistance.
3. NOTE: Use only with the type of gas approved for
this boiler. Refer to the boiler rating plate.
4. NOTE: Install this boiler only in a location and
position as specified in “Locations and Clearances.”
5. NOTE: Provide adequate combustion and venti-
lation air to the boiler space as specified in “Air for
Combustion and Ventilation.”
6. NOTE: Combustion products must be discharged
outdoors. Connect this boiler to an approved vent
system only as specified in the “Venting” section of this
guide.
7. NOTE: Never test for gas leaks with an open
flame. Use a commercially available soap solution
made specifically for the detection of leaks to check all
connections, as specified in “Gas Piping.”
8. NOTE: Always install the boiler to operate within
the boiler’s intended operating temperature range.
9. NOTE: The boiler is not to be used for temporary
heating of buildings or structures under construction.
10.NOTE: Wear appropriate gloves, arm sleeve pro-
tectors, and eye equipment when servicing or maintai-
ning this equipment.
11.NOTE: Verify system is leak free at startup.
During routine boiler maintenance check integrity of
system to be sure there are no leaks. A leak will result
in a continuous flow of make up water leading to pre-
mature heat exchanger failure. Minerals will build up
inside heat exchanger sections reducing performance
and cause section failure. The additional oxygen
added to the system from make up water speeds cor-
rosion inside the heat exchanger. Maintenance and
cleaning must be performed at least once every year.
NOTE: This product must be gas piped by a
licensed Plumber or Gas Fitter in the Com-
monwealth of Massachusetts.

18-CG01D1-4
5
1.0 Safety Considerations................................................................................ 2
1.1 Warnings.................................................................................................................2
1.2 Cautions..................................................................................................................4
2.0 Pre-Installation Information & Instructions............................................ 6
2.1 Parts Included........................................................................................................6
2.2 General Specifications ..........................................................................................7
2.3 Codes and Regulations ..........................................................................................8
2.4 Locations and Clearances......................................................................................8
2.5 Outline Drawings...................................................................................................9
3.0 Installation Instructions.......................................................................... 10
3.1 Moving and Uncrating the Boiler .......................................................................10
3.2 Setting Boiler .......................................................................................................10
3.3 Leveling Boiler .....................................................................................................11
3.4 Water Connections and Piping ............................................................................12
3.5 Typical System Piping Diagrams ........................................................................14
3.6 Combustion Air and Ventilation..........................................................................18
3.7 General Venting Instructions ..............................................................................19
3.8 Auto Vent Damper Instructions ..........................................................................21
3.9 Gas Connections...................................................................................................26
3.10 LP Gas Conversion.............................................................................................27
3.11 High Altitude Derate..........................................................................................30
3.12 Lighting Instructions.........................................................................................30
3.13 Optional Manual Reset Water Temperature Limit Installation .....................31
3.14 Electrical Connections .......................................................................................36
3.15 Supply Water Thermostat (SWT) Settings above 180°F..................................37
4.0 Startup and Adjustments ........................................................................ 38
4.1 Preliminary Inspections ......................................................................................38
4.2 Operating Information.........................................................................................41
5.0 Technical Data.......................................................................................... 42
5.1 Electrical Diagram...............................................................................................42
5.2 Schematic Diagram..............................................................................................43
5.2 Field Wiring Diagrams ........................................................................................44
Table of Contents

18-CG01D1-4
6
WATER TEMPERATURE
WATER PRESSURE
PSI
°F
LOCKOUT -
SERVICE REQUIRED
WATER TEMP
SETTING °F
POWER
OFF - ON
BLANK
INTENTIONALLY 140
160
180
0
I
PRESSURE
TEMPERATURE
GAUGES
OWNER SERVICE
ALERT
(IGNITION LOCKOUT)
SUPPLY WATER
THERMOSTAT
SERVICE DISCONNECT SWITCH
DRAFTHOOD SPILL SWITCH
(BEHIND PANEL IN CONTROL BOX)
AND SENSOR (IN THE DRAFT HOOD)
INTERNALLY CHECKED
PRESSURE PORT
IMMERSION WELL
GAS VALVE
IGNITION
CONTROL
MAIN BURNER
BOILER DRAIN
PILOT LIGHT
FLAME SENSOR
IGNITOR
*INSTALLATION
LOCATION FOR
OPTIONAL MANUAL
HIGH LIMIT RESET
ACCESSORY
BLANK
INTENTIONALLY *
COVER PLATE FOR
FUTURE OPTIONAL
ACCESSORY
2.0 Pre-Installation Information & Instructions
Material in this shipment has been inspected at the factory and released to the transportation
agency without known damage. Inspect exterior of the shipping crate for evidence of rough
handling in shipment. Unpack carefully after moving equipment to the installation location. If
damage to contents is found, report the damage immediately to the delivering agency.
2.1 Parts Included with Boiler
a) Gas fired, natural draft, cast iron water
boiler with electronic ignition and integral draft
hood
b) Factory installed high water temperature
limit switch - auto reset type
c) 1/4 turn Brass Boiler Drain Valve, 1/2” NPT
male x 3/4” NH male hose coupling threads
d) Factory installed flue spillage switch
e) Factory installed ASME approved relief valve
f) Factory installed temperature/pressure gauge
g) Ship with literature package - Installer’s
Guide, Service Facts, Functional Parts List, and
User’s Information Guide
h) Factory installed electrical power switch
i) Factory installed adjustable supply water ther-
mostat with 18° fixed differential
j) Four Adjustable leveling feet, installation
required
k) Automatic vent damper - installation required
l) Manual gas supply shut off valve - installation
required
Figure 1 - Front View with front
Access Panel Removed

18-CG01D1-4
7
2.2 General Specifications - Table 1
Product Specifications
Model1*GBWF090 *GBWF130 *GBWF173 *GBWF215
Ratings
Input BTUH 90,000 130,000 173,000 215,000
DOE Output BTUH 76,000 111,000 145,000 180,000
Net I=B=R® Output BTUH 66,000 96,000 126,000 156,000
AFUE 83.6 83.5 83.4 83.3
Natural Gas Supply
Pilot gas orifice Qty X ID 1 x 0.40mm 1 x 0.40mm 1 x 0.40mm 1 x 0.40mm
Main gas orifices Qty X ID 2 x 3.10mm 3 x 3.10mm 4 x 3.10mm 5 x 3.10mm
Supply pressure (in. w.c.) 7.0 7.0 7.0 7.0
Manifold pressure (in. w.c.) 3.6 3.6 3.6 3.6
LP Gas Supply
Pilot gas orifice Qty X ID 1 x 0.24mm 1 x 0.24mm 1 x 0.24mm 1 x 0.24mm
Main gas orifices Qty X ID 2 x 1.90mm 3 x 1.90mm 4 x 1.90mm 5 x 1.90mm
Supply pressure (in. w.c.) 11.0 11.0 11.0 11.0
Manifold pressure (in. w.c.) 10.6 10.6 10.6 10.6
Heating2
Max working temperature °F 230 230 230 230
Maximum working pressure (psig) 60 60 60 60
Number of Sections 3 4 5 6
Number of burners 2 3 4 5
Boiler water content (gal.) 2.40 3.06 3.72 4.38
Dimensions
Height (inches) 33.46 33.46 33.46 33.46
Width (inches) 15.75 19.69 19.69 23.62
Depth (inches) 24.21 24.21 24.21 24.21
Shipping Weight (lb.) 276 345 406 468
Net Weight (lb.) 234 300 362 421
Gas system connection (NPT male) 1/2” 1/2” 1/2” 1/2”
Heating water supply (NPT male) 1” 1” 1” 1”
Heating water return (NPT female) 1” 1” 1” 1”
Electrical power supply V / Ph / Hz 115 / 60 / 1 115 / 60 / 1 115 / 60 / 1 115 / 60 / 1
Minimum Circuit Ampacity (amps) less than 2.0 less than 2.0 less than 2.0 less than 2.0
Max Overcurrent Protection (amps)15 15 15 15
NOTES:
1. * May be “A” or “T”
2. Boiler is shipped with 30 psi ASME Pressure Relief Valve

18-CG01D1-4
8
2.3 Codes & Regulations
The manufacturer requires installation and services
be in compliance with all applicable codes.
Codes and local utility requirements governing the
installation of gas fired equipment, wiring, plum-
bing, and flue connections must be adhered to. In
the absence of local codes, the installation must
conform with the
a) National Fuel Gas Code ANSI Z223.1 “latest
edition” or CAN/CGA B149 Installation Codes.
The latest code may be obtained from the
American Gas Association Laboratories, 400 N.
Capitol St. NW, Washington D.C. 20001
1-800-699-9277 or www.aga.org
b) Standard for Controls and Safety Devices
for Automatically Fired Boilers, ANSI/ASME
CSD-1 where required.
c) National Electric Code
These boilers have been classified as CATEGORY
I as required by ANSI Z21.47 “latest revision” and
CAN/CGA 2.3. Therefore they “do not require any
special provisions for venting other than what is
indicated in these instructions.”
It is recommended that Manual J of the Air Con-
ditioning Contractors Association (ACCA) or A.R.I.
230 be followed in estimating heating requirements.
When estimating heating requirements for installa-
tion at Altitudes above 2000 ft., remember the gas
input must be reduced (See High Altitude Derate
section 3.9).
2.4 Locations & Clearances
▲
▲
WARNING
!
FIRE HAZARD
DO NOT INSTALL THIS BOILER DIRECTLY
ON CARPETING. FAILURE TO FOLLOW THIS
WARNING CAN RESULT IN PROPERTY DAM-
AGE, PERSONAL INJURY OR DEATH.
NOTE: THIS PRODUCT IS APPROVED FOR
INSTALLATION ON COMBUSTABLE FLOORING
MATERIALS EXCEPT FOR CARPET.
▲
▲
WARNING
!
FIRE HAZARD
DO NOT INSTALL THIS BOILER WHERE FLAM-
MABLE LIQUIDS ARE STORED OR WHERE
FLAMMABLE VAPORS ARE PRESENT.
FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY, DEATH, OR PRO-
PERTY DAMAGE
▲
▲
WARNING
!
SAFETY HAZARD
THESE BOILERS ARE NOT APPROVED OR
INTENDED FOR INSTALLATION IN MANUFAC-
TURED (MOBILE) HOUSING, TRAILERS, OR
RECREATIONAL VEHICLES.
FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY, DEATH, OR PRO-
PERTY DAMAGE
▲
▲
WARNING
!
WATER SAFETY HAZARD
DO NOT USE THIS UNIT IF ANY PART HAS
BEEN UNDER WATER. IMMEDIATELY CALL
A QUALIFIED SERVICE TECHNICIAN TO INS-
PECT THE BOILER AND TO REPLACE ANY PART
OF THE CONTROL SYSTEM AND ANY GAS CON-
TROL WHICH HAS BEEN UNDER WATER.
FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY, DEATH, OR PRO-
PERTY DAMAGE
a) Location Considerations
The location of the boiler is normally selected by
the architect, the builder, or the installer. Before
the boiler is moved into place, be sure to consider
the following requirements:
1. Is the location selected near the chimney or
vent?
2. Do all clearances between the boiler and the
enclosure equal or exceed the minimum clearan-
ces stated in the clearance table on page 9?
3. Is there sufficient space for servicing the
boiler and other equipment? A minimum of 36”
front and top accessibility to the boiler must be
provided. Any access door or panel must permit
removal of the largest component.
4. Are the ventilation and combustion air ope-
nings large enough and will they remain unob-
structed? If outside air is used, are the openings
set above the highest snow accumulation level?
(See page 18 for Combustion and Ventilation
section.)
5. The boiler is approved for installation directly
on combustible flooring. Do NOT install on
carpet.
6. Ensure the floor structure will support the
weight of the boiler.
7. Locate the boiler so that all system compo-
nents are protected from water damage during
operation or service.
8. In some applications, boilers may need to
be raised above the floor level on a solid struc-
ture capable of supporting the boiler in order to
reduce the risk of water damage.
9. In garage applications, refer to ANSI Z223.1
for guidance.
10. All boilers installed above the level of heat
emitters must have a low water cut-off device
installed. Refer to National, State or Local codes
for guidance.
11. Scaling of only 1/8 inch can increase annual
boiler operation cost by 20-25% and lead to over
heating of the boiler sections and premature fail-
ure of the boiler’s heat exchanger. Water hard-
ness is a result of high concentrations of Calcium
and Magnesium suspended in water that become
non-soyable as water is heated. The installing
dealer is required to test boiler’s water source for
water hardness. Water hardness greater than
14 grains per gallon of water will require water
treatment to reduce the affect of the hard water
on the boiler.

18-CG01D1-4
9
b) Minimum Clearances
Table 2
Minimum Clearance
for Combustion Clearance for Service
Top 6” 36”
Right Side 6” See Note 1
Left Side 6” See Note 1
Front 18” 30”
Back 6” 6”
Table 3
*GBWF090A93AVA
*GBWF130A94AVA
*GBWF173A95AVA
*GBWF215A96AVA
4.29
4.57
2.88
3.15
B
4.41
4.69
3.00
3.27
C
1.57
1.85
1.42
1.57
D
5.0
6.0
6.0
7.0
E
Type and model
2.75
3.15
3.15
3.74
A
1/2"
1/2"
1/2"
1/2"
a3
Inlet
gas
1" female
a2
Return
1" male
a1
Supply
15.75
19.68
19.68
23.62
L
NOTES:
1. * May be "A" or "T"
2. All threads are NPT
3. Vent Damper included with boiler.
Field installation required
Effikel Automatic
Vent Damper
KS-5BKF-PP5
KS-6BKF-PP5
KS-6BKF-PP5
KS-7BKF-PP5
1" female1" male
1" female1" male
1" female1" male
2.5 Outline Drawings
Dimensions and Connections - Figure 2
Rear view
Front view Side view
33.46
22.91
7.16
18.90
24.21
a1
a2
a3
All dimensions are in inches
NOTES:
1. Leave clearance on
one side of the boiler
for service access to
back of the boiler.
Minimum 24”

18-CG01D1-4
10
3.0 Installation Instructions
3.1 Moving and Uncrating the Boiler
▲
▲
WARNING
!
SAFETY HAZARD
WHEN MOVING THE BOILER TO THE INSTAL-
LATION LOCATION, ENSURE THE STRUC-
TURE (I.E. FLOORS, STAIRS, PEDESTALS)
CAN SUPPORT THE WEIGHT OF THE BOILER,
DOLLY AND OTHER MOVING EQUIPMENT
AND THE PERSONNEL MOVING THE BOILER.
FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY, DEATH, OR PRO-
PERTY DAMAGE
▲
▲
CAUTION
!
Use caution when inserting and removing safety
blocks. Make sure boiler will not fall off safety
blocks.
Failure to obey caution could result in minor or
moderate injury.
1. Move crated boiler as close as possible to the
location to be installed. Uncrate the boiler
using a saw to cut the four bottom corner
posts even with the top of the pallet. The top
of the crate can then be lifted off of the boiler.
See Figures 3 and 4.
2. If the boiler can not be moved with crate
assembled, uncrate the boiler and use an
appliance dolly to move the boiler to the
selected location. Use a saw to cut the four
corner posts even with the top of the pallet.
The top of the crate can then be lifted off of
the boiler. See Figures 3 and 4.
3. There are four bolts that attach the boiler
to the pallet. The bolts are located near the
four corners of the boiler and are attached
from the bottom side of the pallet. Locate
and use a wrench or socket to remove the
four bolts.
3.2 Setting Boiler
1. Verify the floor structure where the boiler will
be set can support the weight of the boiler.
2. Locate the boiler so all components are pro-
tected from water damage during operation.
3. As required, raise the boiler above the floor
level to reduce the risk of water damage.
4. Consult ANSI Z223.1 for garage applications.
5. Move the boiler to the installation location
with an appliance dolly. If required, the boiler
jacket may be removed to simplify handling.
To remove the boiler jacket, follow the steps listed
below.
a. Remove the front access panel (see Figure 53).
b. Remove the top access panel (see Figure 52).
c. Raise the cover on the control panel (See
Figure 52) and locate the screw access holes
at the top left and right of the panel. Insert
a phillips screwdriver and remove the two
screws. Lower the control box.
d. Remove the left and right boiler jacket panels
by removing the phillips screws securing the
panels.
e. Move and set the boiler.
f. Reassemble the boiler jacket, control panel
and front access panel. Leave the top panel
off until the boiler is leveled using the adju-
stable feet.
Figure 4
When boiler
is ready to be
uncrated, use a
saw to cut the
four vertical
corner boards just
above the base of
the crate.
Figure 3

18-CG01D1-4
11
3.3 Leveling the Boiler
1. Locate the leveling feet (4) shipped in a bag with
the boiler.
2. Use discarded crating material as a safety block.
Tilt the boiler toward the front and place a safety
block under the rear of the boiler, locating it about
1/3 of the way toward the front of the boiler. The
back of the boiler must be elevated high enough
to facilitate installation and adjustment of the
leveling feet. See Figure 5. Remove the safety
block.
3. Tilt the boiler toward the rear and place a safety
block under the front of the boiler, locating it
about 1/3 of the way toward the rear of the boiler.
See Figure 6. Install and adjust front leveling
feet. Remove the safety block.
4. Remove the top panel from the boiler. Place a
torpedo level on top of the metal control box.
Adjust leveling feet to make sure boiler is level
using steps 2 through 3.
Figure 5
Install
Rear Leveling
Feet
Figure 6
Install
Front Leveling
Feet

18-CG01D1-4
12
3.4 Water Connections and Piping
Systems
Overview
For good operation and long life of the boiler, the
piping system must be well proportioned and always
complete with all those accessories that provide
optimum system performance, highest efficiency, and
reliable operation.
Air Vents/Boiler Drain
If the supply and return pipes follow a path where air
pockets could form in certain places, it is advisable
to install an air vents at these points. Also, install a
discharge device at the lowest point in the system to
allow complete draining of the system.
Flow Check Valve
If the boiler is installed at the lowest point of a single
loop system or hydronic coils are used upstream of
air conditioning coils, a flow check valve should be
installed to prevent the natural migration of hot
water through the system in the circulator's off cycle.
Low Water Cutoff
The installer of the boiler is required to provide a low
water cutoff switch when installing the boiler above
the distribution system. Consult local codes which
may require a low water cutoff for all installations
regardless of boiler location. The low water cut off
switch should discontinue burner operation until
proper water level is achieved.
Boiler Protection
The cases where this boiler is installed on systems
with large volumes of water (for example - retro fitted
gravity system), the installer is required to use one
of the methods of boiler protection described in this
manual under "Typical System Piping Diagrams" to
protect the system.
Minimum boiler return temperature is 110°F.
NOTE: Do not use the water system pipes to ground
electrical appliances.
System Water
Before installation, carefully flush all the pipes
of the system with water to remove residues or
impurities that could affect proper operation of the
system. Additives and cleaning solutions are not
recommended. The installing dealer is required to
test the boiler's water source for water hardness.
Water hardness greater than 14 grains per gallon
of water will require water treatment to reduce the
affect of hard water on the boiler. In the presence
of water harder than 14 grains per gallon, we
recommend the use of suitably conditioned water in
order to avoid possible scaling in the boiler, caused
by hard water, or corrosion produced by aggressive
water. It should be remembered that, because of its
low thermal conductivity, even scaling of just a few
mm thick causes significant overheating of the boiler
walls.
Pipe Connections
Connection of supply and return water connections
are located on the back of the boiler. The installation
of piping shall be in accordance with National, State
and local codes.
1. Pipe Connections
a) Supply and Return connections are 1” NPT.
See Figure 7. The pressure relief valve assem-
bly is factory installed in all natural draft
models.
b) The Gas connection is 1/2” NPT. See Figure
7.
c) Boiler drain ships installed from factory. See
Figure 1.
Figure 8
FLUE GAS
SPILL SWITCH
SENSOR
RETURN 1" NPT
INTEGRAL DRAF
T
HOOD
SUPPLY 1" NPT
GAS 1/2" NPT
Figure 7

18-CG01D1-4
13
Isolation Valves
It is advisable to install isolation valves between the
boiler and heating system and on the inlet and outlet
side of all hydronic system components for service.
This allows the boiler or components to be isolated
from the system if necessary.
Note: Ensure the hydronic pipe system is
properly supported so that no stress is applied
to the boiler connections.
Proper Boiler Operating Pressures
The system pressure when cold should be about 12psi.
For correct operation of the boiler, when hot, its pressure
should be about 18-24 psi.
Figure 9
Head Loss vs. Flow Chart for All *GBWF Models
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
0 5 10 15 20 25
Water Flow (GPM)
Head Loss (Ft.)
Loss of Head for the entire range of 3 to 6 heat exchanger sections
▲
▲
WARNING
!
SAFETY HAZARD.
PRESSURE RELIEF VALVE OUTLET MUST BE
ROUTED TO WITHIN 6” OF A FLOOR DRAIN OR
OTHER AREA SAFE FOR DISCHARGE OF HOT
WATER AND SAFE FROM FREEZING. THIS
PIPE MUST BE FULLY 3/4” IN SIZE THE ENTIRE
LENGTH AND IT MUST NOT CONTAIN ANY
RESTRICTIONS, TRAPS, VALVES, PLUGS, OR
CAPS.
FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY, DEATH, OR PRO-
PERTY DAMAGE

18-CG01D1-4
14
3.4 Typical System Piping Diagram
Back Flow
Preventer
Globe
Valve
Globe
Valve
Globe
Valve
Pressure
Reducer
Pressure
Gauge
Air
Separator
Circulator
Pump
Flow
Check
Boiler
Heat Emitter
Heat Emitter
Baseboard
Convection
Fin Tube
Expansion Tank
Exhaust Vent
Return
Return water temperature must be above 110OF
Supply
Typical System Piping Diagram
Single Zone System - High Temperature with Low Mass Heat Emitters
Relief
Valve
1
1
NOTES: Locate circulator inlet close to connection point of the expansion tank, but allow at least the equivalent of 10 to 12 pipe diameters between the circulator pump and the expansion tank to reduce the possibility of pump noise and facilitate air removal.

18-CG01D1-4
15
Circulator
Pump
Circulator
Pump 3-Way
Motorized Valve
Boiler
Back Flow
Preventer
Globe
Valve
Globe
Valve
Globe
Valve
Pressure
Reducer
Pressure
Gauge
Air
Separator
Expansion Tank
Exhaust Vent
Return
Supply
Typical System Piping Diagram
Primary Secondary Loop with 3-way Motorized Valve Low Temperature with Low Mass Heat Emitters or High Temperature with High or Low Mass Heat Emitters
Return Water
Temperature
Sensor
Supply Water
Temperature
Sensor
Heat Emitter
Return water temperature must be above 110OF
NOTES: Protects boiler from too low return water temperature and condensation. Locate circulator inlet close to connection point of the expansion tank, but allow at least the equivalent of 10 to 12 pipe diameters between the circulator pump and the expansion tank to reduce the possibility of pump noise and facilitate air removal. Close coupled Tees
Relief
Valve
1
2
1
2
3
3

18-CG01D1-4
16
Circulator
Pump
4-Way Motorized Valve
Boiler
Back Flow
Preventer
Globe
Valve
Globe
Valve
Globe
Valve
Pressure
Reducer
Pressure
Gauge
Air
Separator
Expansion Tank
Exhaust Vent
Return
Supply
Typical System Piping Diagram
Primary Secondary Loop with 4-way Motorized Valve with Circulator in Secondary Loop Low Temperarure with Low Mass Heat Emitters or High Temperature with High or Low Mass Heat Emitters
Return Water
Temperature
Sensor
Supply Water
Temperature
Sensor
Return water temperature
must be above 110OF
Relief
Valve
Heat Emitter
1
2
1
2
NOTES: Protects boiler from too low return water temperature and condensation. Locate circulator inlet close to connection point of the expansion tank, but allow at least the equivalent of 10 to 12 pipe diameters between the circulator pump and the expansion tank to reduce the possibility of pump noise and facilitate air removal.

18-CG01D1-4
17
4-Way Motorized Valve
Boiler
Back Flow
Preventer
Globe
Valve
Globe
Valve
Globe
Valve
Pressure
Reducer
Pressure
Gauge
Air
Separator
Expansion Tank
Exhaust Vent
Return
Supply
Typical System Piping Diagram
Primary Secondary Loop with 4-way Motorized Valve Low Temperarure with Low Mass Heat Emitters or High Temperature with High or Low Mass Heat Emitters
Circulator
Pump
Circulator
Pump
Return Water
Temperature
Sensor
Supply Water
Temperature
Sensor
Return water temperature
mustbeabove110
OF
Relief
Valve
Heat Emitter
2
1
2
1
3
3
NOTES: Protects boiler from too low return water temperature and condensation. Locate circulator inlet close to connection point of the expansion tank, but allow at least the equivalent of 10 to 12 pipe diameters between the circulator pump and the expansion tank to reduce the possibility of pump noise and facilitate air removal. Close coupled Tees

18-CG01D1-4
18
3.6 Combustion Air and Ventilation
Important: All aspects of the installation of this
boiler, including materials, methods of providing
combustion air and methods of venting products of
combustion to the outdoors must comply with all
local codes and the following national standards:
1) CSA B149.1 (most recent edition) - Natural Gas
and Propane Installation Code (Canada)
2) NFPA 54 (most recent edition) - National Fuel Gas
Code (US)
3) NFPA 58 (most recent edition) - Liquefied Petro-
leum Gas Code (US)
Adequate flow of combustion and ventilating air
must not be obstructed from reaching the boiler.
Air openings provided in the boiler casing must be
kept free of obstructions which restrict the flow of
air. Airflow restrictions affect the efficiency and safe
operation of the boiler. Keep this in mind should you
choose to remodel or change the area which contains
your boiler. Boilers must have a free flow of air for
proper performance.
Provisions for combustion and ventilation air shall
be made in accordance with “latest edition” of Sec-
tion 5.3, Air for Combustion and Ventilation, of the
National Fuel Gas Code, ANSI Z223.1, or Sections
7.2, 7.3 or 7.4 of CAN/CGA B149 Installation Codes,
and applicable provisions of the local building codes.
Special conditions created by mechanical exhaust air
and fireplaces must be considered to avoid unsatis-
factory boiler operation.
Boiler locations may be in “unconfined space” or
“confined space”. Unconfined space is defined in
Table 4 and Figure 10.
TABLE 4
Minimum Area in Square Feet for Unconfined
Space Installations
Boiler Maximum
BTUH / Input Rating With 8 Foot Ceiling Minimum Area in Square
Feet of Unconfined
Space
90,000 560
130,000 810
173,000 1080
215,000 1340
TABLE 5
Minimum Free Area in Square Inches Each
Opening (Boiler Only)
Boiler
Maximum
BTUH /
Input Rating
Air From
Inside Air From Outside
Vertical
Duct Horizon- tal Duct
90,000 100 25 50
130,000 130 35 70
173,000 175 45 90
215,000 215 55 110
50 CU. FT. OR MORE
PER 1000 BTU/HR. INPUT
ALL EQUIP. INSTALLED
UNCONFINED
Fig. 10
CONFINED
LESS THAN 50 CU. FT.
PER 1000 BTU/HR. INPUT
ALL EQUIP INSTALLED
Fig. 11
These spaces must have adequate air by infiltration
to provide air for combustion, ventilation, and dilu-
tion of flue gases. Buildings with tight construction
(for example, weather stripping, heavily insulated,
caulked, vapor barrier, etc.), may need additional air
provided as described for confined space.
Confined spaces are installations with less than 50
cu. ft. of space per 1000 BTU/hr input from all equip-
ment installed as in Figure 11.
Air for combustion and ventilation requirements can
be supplied from inside the building as in Figure 12
or from the outdoors, as in Figure 13 (see page 19).
1. All air from inside the building as in Figure 12:
The confined space shall be provided with two
permanent openings communicating directly
with an additional room(s) of sufficient volume so
that the combined volume of all spaces meets the
criteria for an unconfined space. The total input
of all gas utilization equipment installed in the
combined space shall be considered in making
this determination. Refer to Table 4, for mini-
mum open areas required.
2. All air from outdoors as in Figure 13: The con-
fined space shall be provided with two permanent
openings, one commencing within 12 inches of
the top and one commencing within 12 inches of
the bottom of the enclosure. The openings shall
communicate directly, or by ducts, with the out-
doors or spaces (crawl or attic) that freely com-
municate with the outdoors. Refer to Table 5, for
minimum open areas required.

18-CG01D1-4
19
3. The following types of installations will require use
of OUTDOOR AIR for combustion, due to chemi-
cal exposures:
* Commercial buildings
* Buildings with indoor pools
* Boilers installed in commercial laundry rooms
* Boilers installed in hobby or craft rooms
* Boilers installed near chemical storage areas.
Exposure to the following substances in the com-
bustion air supply will also require OUTDOOR AIR
for combustion:
* Permanent wave solutions
* Chlorinated waxes and cleaners
* Chlorine based swimming pool chemicals
* Water softening chemicals
* Deicing salts or chemicals
* Carbon Tetrachloride
* Halogen type refrigerants
* Cleaning solvents (such as perchloroethylene)
* Printing inks, paint removers, varnish, paint,
etc.
* Hydrochloric acid
* Cements and glues
* Antistatic fabric softeners for clothes dryers
* Masonry acid washing materials
Figure 12
Figure 13
3.7 GENERAL VENTING
INSTRUCTIONS
▲WARNING
!
CARBON MONOXIDE POISONING HAZARD
FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN CARBON MONOXIDE POISONING OR
DEATH.
VENT PIPING
These boilers have been classified as Natural Draft,
Category I boilers under the “latest edition” provi-
sions of ANSI Z21.13 and CAN/CGA 4.9 standards.
Category I boilers operate with a non-positive vent
static pressure and with a flue loss of not less than 17
percent.
The boiler shall be connected to a factory built
chimney or vent complying with a recognized
standard, or a masonry or concrete chimney
lined with a lining material acceptable to the
authority having jurisdiction.

18-CG01D1-4
20
VENT PIPING
▲
▲
WARNING
!
CARBON MONOXIDE, FIRE, AND/OR SMOKE
HAZARD
CARBON MONOXIDE, FIRE, OR SMOKE CAN
CAUSE SERIOUS BODILY INJURY, DEATH, AND/
OR PROPERTY DAMAGE.
FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN CARBON MONOXIDE POISONING
OR DEATH.
1. Avoid an excessive number of bends.
2. Horizontal runs should pitch upward at least 1/4"
per foot. See Table 6 and Figure 14.
3. Horizontal runs should be as short as possible.
4. All vent pipe or connectors should be securely
supported and must be inserted into, but not
beyond the inside wall at the chimney vent.
5. When vent connections must pass through walls
or partitions of combustible material, a thimble
must be used and installed according to local
codes.
6. Vent pipe through the roof should be extended to
a height determined by National Fuel Gas Code
or local codes. It should be capped properly to
prevent rain water from entering the vent. Roof
exit should be waterproofed.
7. Use type “B” double wall vent when vent pipe is
routed through cool spaces (below 60° F.).
8. Apply other good venting practices as stated in
the venting section of the National Fuel Gas
Code ANSI Z223.1 “latest edition”.
9. Vent connectors serving appliance vented
by natural draft or non-positive pressure
shall not be connected into any portion of a
mechanized draft system operating under
positive pressure.
10. Horizontal pipe runs must be supported by han-
gers, straps or other suitable material in inter-
vals at a minimum of every 3 feet of pipe.
11. A boiler shall not be connected to a chimney
or flue serving a separate appliance desi-
gned to burn solid fuel.
12. The flow area of the largest section of vertical
vent or chimney shall not exceed 7 times the
smallest listed appliance categorized vent area,
flue collar area, or draft hood outlet area unless
designed in accordance with approved enginee-
ring methods.
Maximum Vent or Tile
Lined Chimney Flow Area
*Drafthood outlet diameter, flue collar diameter, or
listed appliance categorized vent diameter. Maximum
vent or tile lined chimney flow area values are for chimnies
that are not exposed to the outdoor, below the roof line. If
exposed below the roof line, then local gas utility and/or
authority having jurisdiction must be consulted.
π(D*)2
4
= X 7
TABLE 6
Gas Vent Termination
Roof Pitch Minimum Height
Flat to 7/12 1.0 Feet*
Over 7/12 to 8/12 1.5 Feet
Over 8/12 to 9/12 2.0 Feet
Over 9/12 to 10/12 2.5 Feet
Over 10/12 to 11/12 3.25 Feet
Over 11/12 to 12/12 4.0 Feet
Over 12/12 to 14/12 5.0 Feet
Over 14/12 to 16/12 6.0 Feet
Over 16/12 to 18/12 7.0 Feet
Over 18/12 to 20/12 7.5 Feet
Over 20/12 to 22/12 8.0 Feet
* This requirement covers most instal-
lations
A variety of potential sources of carbon monoxide can
be found in a building or dwelling such as gas-fired
clothes dryers, gas cooking stoves, water heaters,
boilers and fireplaces. The U.S. Consumer Product
Safety Commission recommends that users of gas-
burning appliances install carbon monoxide detectors
as well as fire and smoke detectors per the manufac-
turer’s installation instructions to help alert dwelling
occupants of the presence of fire, smoke or unsafe
levels of carbon monoxide. These devices should be
listed by Underwriters Laboratories, Inc. Standards
for Single and Multiple Station CarbonMonoxide
Alarms, UL 2034 or CSA International Standard,
Residential Carbon Monoxide Alarming Devices, CSA
6.19.
Figure 14
NOTE: The manufacturer of your boiler does NOT
test any detectors and makes no representations
regarding any brand or type of detector.