Operating instructions

15
Part Number 550-142-784/0812
GWA Series 2 Gas-Fired Water Boilers – Boiler Manual
Fill the system with water
1. Closemanualandautomaticairventsandboilerdraincock.
2. Fill to correct system pressure. Correct pressure will vary
with each application.Typical cold water ll pressure for a
residential system is 12 psi.
3. Purgeairfromsystem:
a. Connectahosetopurgevalveorvalves,ifinstalled.Route
hose to an area where water can drain and be seen.
b. Close the boiler or system isolation valve between the
purge valve and fill connection to the system.
c. Closezoneisolationvalves.
d. Openquick-llvalveoncoldwatermakeupline.
e. Open purge valve.
f. One zone at a time, open the isolation valves. Allow
water to run through the zone, pushing out the air. Run
until no noticeableair ow is present. Close the zone
isolationvalvesandproceedwiththenextzone.Follow
this procedure until all zones are purged.
g. Closethequick-llwatervalveandpurgevalveandremove
the hose. Open all isolation valves. Watch that system
pressure rises to correct cold-fill pressure.
h. After the system has operated for a while, eliminate
any residual air by using the manual air vents located
throughout the system.
i. Ifpurgevalvesarenotinstalledinsystem,openmanualair
vents in system one at a time, beginning with lowest floor.
Closeventwhenwatersquirtsout.Repeatwithremaining
vents.
4. Open automatic air vent (diaphragm-type or bladder-type
expansiontanksystemsonly)oneturn.
5. Open other vents:
a. Starting on the lowest floor, open air vents one at a time
until water squirts out.
b. Repeat with remaining vents.
6. Refill to correct pressure.
Inspect system water piping
Afterllingtheboilerandsystemwith water,inspectallpiping
throughout the system for leaks. If found, repair immediately.
Repeatthisinspectionaftertheboilerhasbeenstartedandthe
system has heated up.
 Leaksmustberepairedatonce.Failuretodosocan
damage the boiler, resulting in substantial property
damage.
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Severe damage to boiler
will occur, resulting in substantial property damage.
Determine if water treatment is needed
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Severe damage to
boiler will occur, resulting in substantial property
damage.
 Eliminateallsystemleaks.Continualfreshmakeup
waterwillreduceboilerlife.Mineralscanbuildup
insections,reducingheattransfer,overheatingcast
iron,andcausingsectionfailure.
Verify water chemistry
Consultlocalwatertreatmentcompaniesforunusuallyhardwater
areas (above 7 grains hardness) or low pH water conditions (below
7.0).BoilerwaterpHof7.0to8.5isrecommended.
Freeze protection (when used)
Useantifreezemadeespeciallyforhydronicsystems. Inhibited
propylene glycol is recommended.
Do not use ethylene glycol, automotive or undiluted
antifreeze.Severepersonalinjuryordeathcanresult.
1. Determine antifreeze quantity according to system water
content. Boiler water content is listed on Page 46. Remember
toincludeexpansiontankwatercontent.
2. Followantifreezemanufacturer’sinstructions.
3. A50%solutionofpropyleneglycol/waterprovidesmaximum
protection to about -30 °F.
4. Local codes may require back flow preventer or actual
disconnectfromcitywatersupply.
5. Whenusingantifreezeinasystemwithautomaticll,installa
watermetertomonitorwatermakeup.Glycolwillleakbefore
thewaterbeginstoleak,causingglycolleveltodrop.Added
waterwilldilutetheantifreeze,reducingthefreezeprotection
level.
Check for gas leaks
 Beforestartingtheboiler,andduringinitialoperation,
smellneartheoorandaroundtheboilerforgas
odorant or any unusual odor. Do not proceed with
start-upifthereisanyindicationofagasleak.Repair
anyleakatonce.
 Propaneboilersonly—Yourpropanesuppliermixes
anodorantwiththepropanetomakeitspresence
detectable.Insomeinstances,theodorantcanfade
and the gas may no longer have an odor.
• Propanegascanaccumulateatoorlevel.Smell
neartheoorforthegasodorantoranyunusualodor.
Ifyoususpectaleak,donotattempttolightthepilot.
• Usecautionwhenattemptingtolightthepropane
pilot. This should be done by a qualified service
technician,particularlyifpilotoutagesarecommon.
• Periodicallychecktheodorantlevelofyourgas.
• Inspectboilerandsystematleastyearlytomake
sureallgaspipingisleak-tight.
• Consultyourpropanesupplierregardinginstallation
ofagasleakdetector.Therearesomeproductson
themarketintendedforthispurpose.Yoursupplier
may be able to suggest an appropriate device.
6 Start-up
Preparation
Inspect base insulation
Checktomakesureinsulationissecureagainstallfoursidesof
thebase.Ifinsulationisdamagedordisplaced,donotoperate
boiler. Replace or reposition insulation.
Failure to replace damaged insulation or reposition
insulation can result in a fire hazard, causing
severe personal injury, death or substantial property
damage.
The boiler contains ceramic fiber and fiberglass
materials.Usecarewhenhandlingthesematerials
per instructions on page 39ofthismanual.Failure
to comply could result in severe personal injury.