Operating instructions

29
Part Number 550-142-784/0812
GWA Series 2 Gas-Fired Water Boilers – Boiler Manual
12 Troubleshooting
 Verifyproperoperationafterservicing.•Seevent
damper manufacturer’s instructions packed with
ventdamper for additional information. Failure to
comply could result in severe personal injury, death
or substantial property damage.
Figure 15 Manually opening vent damper
 Labelallwirespriortodisconnectionwhenservicing
controls. Wiring errors can cause improper and
dangerous operation.
 Neverjumper(bypass)rolloutthermalfuseelement
oranyotherdeviceexceptformomentarytestingas
outlined in Troubleshooting Charts. Severe personal
injury, death or substantial property damage can result.
Burner access panel must be in position during
boiler operation to prevent momentary flame rollout
onignitionofmainame.Severepersonalinjuryor
substantial property damage will result.
Before troubleshooting:
1. Havethefollowingitems:
a. Voltmeterthatcancheck120VACand24VAC.
b. Microammeterwithascalerangeof0-10.
c. Continuitychecker.
d. U-tubemanometer.
2. Checkfor120VAC(minimum102VACtomaximum132VAC)
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.
Troubleshooting sequence:
1. Beforeproceeding,checkfor:
• Looseconnections,blownfuseorserviceswitchoff?
• Boiler temperature adjustment, set below boiler water
temperature?
• Thermostatsetbelowroomtemperature?
• Gasnotturnedonatmeterorboiler?
• Incominggaspressurelessthan:
 5”w.c.fornaturalgas?11”w.c.forpropanegas?
2. Ifalloftheabovecheckcorrectly,checkgaspressures:
a. Withboileroff
• 13”w.c.maximumnaturalorpropanegaspressure
upstreamofgasvalve.
b. With boiler on:
• 5” w.c. minimum natural gas pressure or 11”w.c.
propanegaspressureupstreamofgasvalve.
• 3.5” w.c. minimum natural gas pressure or 10”w.c.
propane gas pressure downstream tapping on gas
valve—Canbeadjustedbyregulatorongasvalve.
c. Ifgaspressureisincorrectorgasisnotavailabletoboiler,
contactgassuppliertocorrectbeforeproceedingfurther.
3. Checkpilotoperation-Follow“OperatingInstructions”,pages
23 and 24.
• Ifgasisavailableandyoucannotobtainapilotame,try
purging the gas line and cleaning pilot and pilot gas tubing.
Follow“OperatingInstructions”again.
In event of vent damper failure:
Effikal or Field Controls vent damper
If troubleshootingchart recommends replacing actuator and
actuatorisnotimmediatelyavailable,damperbladecanbexed
in an open position to allowboiler operation.Manually turning
blade can cause actuator damage. Follow these instructions only
incaseofnoheatordamperactuatormalfunction.
1. MovedamperserviceswitchtoHoldDamperOpenposition.
Applycallforheattoboiler.Damperbladeshouldthenrotate
to Open position and boiler will fire.
2. Ifstep1doesnotopendamper,manuallyrotatedamperblade
toopenpositionusingwrenchorpliersonatshaftbetween
damperandactuator.Boilerwillre.Verifythatdamperservice
switch is in Hold Damper Open position. (Figure 15)
3. Do not leave vent damper permanently in this position. Replace
actuatorimmediately.IfventdamperisleftinOpenposition,
boilerwillnotoperateatpublishedefciencies.
Johnson Controls vent damper
If troubleshootingchart recommends replacing actuator and
actuator is not immediately available, damper blade can be
xedinanopenpositiontoallowboileroperation.Followthese
instructionsonlyincaseofnoheatordamperactuatormalfunction.
See Figure 15.
1. Turnoffpowertoboiler.
 Failure to turn off power to boiler can result in
severe personal injury, death or substantial property
damage.
2. Seeventdampermanufacturer’sinstructionsforprocedureto
xventdamperinopenposition.
3. Turn on power to boiler.
4. Usingwrenchorpliersonatshaftsection,manuallyrotate
damper bladeuntil green light turns on. Boiler will fire.
(Figure 15)
5. Do not leave vent damper permanently in this position. Replace
actuatorimmediately.IfventdamperisleftinOpenposition,
boilerwillnotoperateatpublishedefciencies.
Effikal or Field
Controls damper
Johnson Controls
damper
72508
Closed
Open
Damper blade
indicator
Wrench
or pliers