Operating instructions

26
Part Number 550-142-784/0812
GWA Series 2 Gas-Fired Water Boilers – Boiler Manual
The boiler should be inspected and started annually,
at the beginning of the heating season, only by
a qualified service technician. In addition, the
maintenanceandcareoftheboilerdesignatedin
Table 6, page 25 andexplainedonthefollowing
pages must be performed to assure maximum
boiler efciency and reliability. Failure to service
and maintain the boiler and system could result in
equipmentfailure.
 Electricalshockhazard—Turnoffpowertotheboiler
beforeanyserviceoperationontheboilerexcept
as noted otherwise in this manual. Failure to turn
offelectricalpowercouldresultinelectricalshock,
causing severe personal injury or death.
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.
Reported problems
Inspect any problems reported by owner and correct before
proceeding.
Boiler area
1. Verify thatboilerareaisfreeof anycombustiblematerials,
gasoline and other flammable vapors and liquids.
2. Verify thatboilerarea (and airintake)isfreeof any of the
contaminants listed in Table 2 on page 5ofthismanual.Ifany
ofthesearepresentintheboilerintakeairvicinity,theymust
beremoved.Iftheycannotberemoved,installcombustionair
piping to the boiler in accordance with national, provincial or
local codes.
Air openings
1. Verify that combustion and ventilation air openings to the
boilerroomand/orbuildingareopenandunobstructed.Check
operationandwiringofautomaticcombustionairdampers,if
used.
2. Verifythatboilerventdischargeandairintakearecleanand
freeofobstructions.
Flue gas vent system
1. Visuallyinspectentireuegasventingsystemforblockage,
deteriorationorleakage.Repairanyjointsthatshowsignsof
leakageinaccordancewithventmanufacturer’sinstructions.
2. Verify that masonry chimneys are lined, lining is in good
condition, and there are not openings into the chimney.
 Failuretoinspectfortheaboveconditionsandhave
them repaired can result in severe personal injury
or death.
Pilot and main burner flames
1. Visually inspect pilot burner and main burner ames as
directed under Section 6, page 17ofthismanual.
11 Service and maintenance continued
Water piping
1. Checktheboilerinteriorpipingandallsystempipingforsigns
ofleaks.
2. Repairanyleaksbeforeproceeding.
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orboilerleaks.Continualfresh
makeupwaterwillreduceboilerlife.Mineralscan
buildup in sections,reducingheattransfer,over-
heatingcastiron,andcausingsectionfailure.Leak-
ing water may also cause severe property damage.
Boiler heating surfaces
1. Disconnecttheventpipeattheboilerdrafthoodandremove
drafthoodafterturningoffpowertotheboiler.
2. Useabrightlighttoinspecttheboileruecollectorandheating
surfaces.
3. Iftheventpipeorboilerinteriorsurfacesshowevidenceof
soot,follow“Cleaningboilerheatingsurfaces”inthismanual
section, page 28. Remove the flue collector and clean the
boiler if necessary after closer inspection of boiler heating
surfaces.
4. Ifthereisevidenceofrustyscaledepositsonboilersurfaces,
checkthewaterpipingandcontrolsystemtomakesurethe
boiler return water temperature is properly maintained (per
this manual).
5. Reconnectventanddrafthood.Replaceallboilercomponents
beforereturningtoservice.
6. Checkinsideandaroundboilerforevidenceofanyleaksfrom
theboiler.Iffound,locatesourceofleaksandrepair.
Burners and base
1. Afterturningoffpowertotheboiler,removethejacketdoor
and base access panel (Figure 19, item 4, page 40).
2. Inspectburnersandallothercomponentsintheboilerbase.
3. Ifburnersmustbecleaned,raiserearofeachburnertorelease
fromsupportslot,slideforwardandremove.Thenbrushand
vacuumtheburnersthoroughly,makingsureallportsarefree
ofdebris.Carefullyreplaceallburners,makingsureburner
with pilot bracketis replaced in its original positionand all
burners are upright (ports up).
4. Inspectthebaseinsulation.
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.
a. Verifythattheinsulationisintactandsecureagainstall
foursidesofthebase.
 Ifinsulationisdamagedordisplaced,donotoperate
the boiler. Replace or reposition insulation as
necessary. Failure to replace damaged insulation
can result in a fire hazard, causing severe personal
injury, death or substantial property damage.
o Inspect . . . . . . . . . .
o Inspect . . . . . . . . . .