19
Part Number 550-142-785/0812
GWI
Series 2
Gas-Fired Water Boilers –
Boiler Manual
Operate boiler
DO NOT proceed with boiler operation unless boiler
and system have been filled with water and all in-
structions and procedures of previous manual sec
-
tions have been completed. Failure to do so could
result in severe personal injury, death or substantial
property damage. Before starting the boiler . . .
• Read manual
Sections 9 and 10
and the “Operating
instructions”, page 26.
• Verify the boiler and system are full of water.
• Verify the Start-up “Preparation” procedures of this
section have been completed.
Adjust boiler control settings
BOILER OPERATING TEMPERATURE
With power turned on, control module receives a signal from
the temperature sensor and displays boiler temperature. The
control knob labeled BOILER TEMP is used to adjust the
operating temperature setpoint, turning clockwise to increase
temperature setting and counterclockwise to decrease. When the
knob is turned to adjust temperature the display will brighten to
indicate adjustment mode. After temperature is set to desired
value, display will dim after approximately 5 seconds to indicate
measurement mode.
ADJUST BOILER OPERATING TEMPERATURE TO
DESIRED SETPOINT
BOILER ECONOMY SETTING
To comply with Department of Energy regulations, the control
module circulates available hot water before turning on the boiler
to attempt to satisfy a call for heat. While attempting to satisfy
the heat demand, the control module also monitors the boiler
temperature changes via the temperature sensor and determines
whether or not the available hot water will satisfy the demand,
adjusting the time delay to turn on the boiler until it determines
that additional heat will be needed. The knob labeled ECONOMY
ADJUST provides an adjustment between maximize (MAX) and
minimize (MIN) the delay. The maximum (MAX) adjustment
position should be used to maximize energy savings. Turning the
knob counterclockwise decreases the delay time and should only
be used in the event that the heated space becomes uncomfortable.
ADJUST ECONOMY TO DESIRED POSITION
(MAX IS THE PREFERRED SETTING)
IMPORTANT
In accordance with Section 325 (f) (3) of the Energy Policy
and Conservation Act, this boiler is equipped with a feature
that saves energy by reducing the boiler water temperature
as the heating load decreases. This feature is equipped with
an override which is provided primarily to permit the use of
an external energy management system that serves the same
function.
7 Start-up
continued
THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST
ONE OF THE FOLLOWING CONDITIONS IS TRUE:
•
An external energy management system is installed that
reduces the boiler water temperature as the heating load
decreases.
•
This boiler is part of a modular or multiple boiler system
having a total input of 300,000 BTU/hr or greater.
•
This boiler is equipped with a tankless coil.
Start the boiler
Follow the “Operating instructions”,
page 26.
If boiler fails to start, see “If boiler doesn’t start . . . Check for:”
on this page.
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 se-
vere 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
page 16
of this manual.
5. Verify operation using procedures below. Perform “Checkout
procedure” on pages 20 and 21
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 “Troubleshoot
-
ing”, page 31
of this manual.
