GWA
Gas-Fired Water Boilers –
Boiler Manual
16
Part Number 670 01 1001 00
Check system and boiler
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.
If you discover evidence of any gas leak, shut down
the boiler at once. Find the leak source with bubble
test and repair immediately. Do not start boiler again
until corrected. Failure to comply could result in
severe personal injury, death or 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.
1. Check system piping for leaks. If found, shut down boiler and
repair immediately.
2. Vent air from system using manual vents. Air in the system will
interfere with circulation and cause heat distribution problems
and noise.
3. Inspect vent system thoroughly for signs of deterioration from
corrosion, physical damage or sagging. Verify that masonry
chimney liners are in good condition, with no obstructions, and
there are no openings into the chimney.
4. Check around the boiler for gas odor following the procedure of
“Check for gas leaks”, page 15.
5. Verify operation using procedures below. Perform “Checkout
procedure”, page 18, and fill in the “Installation and service
certificate”.
If boiler doesn’t start . . . Check for:
1. Loose connections, blown fuse or service switch off?
2. High limit switch set below boiler water temperature?
3. Thermostat set below room temperature?
4. Gas not turned on at meter or boiler?
5. Incoming gas pressure less than:
5" w.c. for natural gas? 11" w.c. for propane gas?
6. If none of the above corrects the problem, see
“Troubleshooting”, Section 11, page 27.
6
Start-up
continued
Operate boiler
DO NOT proceed with boiler operation unless boiler
and system have been filled with water and all
instructions and procedures of previous manual
sections have been completed. Failure to do so could
result in severe personal injury, death or substantial
property damage. Before starting the boiler . . .
• See pages 20 and 21, for standing pilot boiler “Lighting
Instructions”, or the Control Supplement for spark-
ignited pilot “Operating Instructions”.
• Verify the boiler and system are full of water (or glycol/
water mixture, if used).
• Verify the “Preparation” procedures of page 15 have
been completed.
Start the boiler
Follow the “Lighting or Operating Boiler Instructions” from:
•
Standing pilot boilers — Manual pages 20 and 21.
•
Spark-ignited pilot boilers — See Control Supplement.
Remove boiler jacket door and note the gas valve manufacturer
and model number.
See either page 20 or page 21, depending on gas valve installed in
boiler. Use only the “Lighting Instruction” which applies to this gas
valve. (The “Lighting Instruction” label on the boiler provides the
same information.)
If boiler fails to start, see “If boiler doesn’t start . . . Check for:” on
this page.
GWA
Gas-Fired Water Boilers –
Boiler Manual
21
Part Number 670 01 1001 00
9
Lighting Instructions — GWA standing pilot boilers
Robertshaw 7200 gas valve
FOR YOUR SAFETY READ BEFORE LIGHTING
If you do not follow these instructions exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if service is to be
performed.
3. Remove front panel.
4. Depress and move selector arm left
to OFF.
5. Replace front panel.
LIGHTING INSTRUCTIONS
WHAT TO DO IF YOU SMELL GAS
•
Do not try to light any appliance.
•
Do not touch any electric 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.
A. This appliance has a pilot, which must be
lighted by hand. When lighting the pilot, follow
these instructions exactly.
B. Before LIGHTING, smell all around the
appliance area for gas. Be sure to smell next
to the floor because some gas is heavier than
air and will settle on the floor. See below.
C. Use only your hand to push down the reset button or turn the gas control
knob. Never use tools. If the knob or reset button will not operate by hand,
don't try to repair it, call a qualified service technician. Force or attempted
repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under water. Immediately call
a qualified service technician to inspect the appliance and to replace any
part of the control system and any gas control, which has been under water.
1. Stop! Read the safety information above on this label.
2. Set the thermostat to lowest setting.
3. When equipped with Effikal vent damper Model RVGP, place
service switch in Hold Damper Open position.
4. Turn off all electrical power to the appliance.
5. When equipped with Johnson Controls vent damper Model
M35, manually rotate damper blade in direction of arrow to
Open position indicated on damper assembly.
6. Depress and move selector arm left
to OFF.
7. When equipped with vent damper, verify damper blade is in
full open position.
8. Wait five (5) minutes to clear out any gas. Then smell for
gas, including near the floor. If you smell gas, STOP! Follow
"B" in the safety information above. If you don't smell gas,
go to the next step.
9. Remove access panel located above burners.
10. Find pilot — follow metal tube from gas control.
The pilot is between two burners behind the
access panel.
11. Move selector arm on gas control right
to SET position.
12. Hold selector arm in SET position and immediately light the
pilot with a match. Continue to hold selector arm to SET for
about one-half (
1
/
2
) minute after the pilot is lit.
13. Release selector arm. If pilot does not remain lit, repeat steps
6 through 13.
•
If the pilot will not stay lit after several tries, move selector
arm left
to OFF and call your service technician or gas
supplier.
14. Replace access panel.
15. Turn selector arm left
to ON.
16. Turn on all electric power to the appliance.
17. When equipped with Effikal vent damper, place service
switch in Automatic Operation position.
18. Set thermostat to desired setting.
19. Replace front panel.
TO TURN OFF GAS TO THE APPLIANCE
