18
Part Number 550-142-785/0812
GWI
Series 2 Gas-Fired Water Boilers – Boiler Manual
Check for gas leaks
Beforestartingtheboiler,andduringinitialopera-
tion,smellneartheoorandaroundtheboilerfor
gas odor
ant or any unusual odor. Do not proceed
with
star
t-up
if
there
is
an
y
indication
of
a
gas
leak.
Repair
anyleakatonce.
Propaneboilersonly—Yourpropanesuppliermixes
anodorantwiththepropanetomakeitspresence
de
tectable.
Inso
me
i
nstances,
th
e
od
orant
ca
n
f
ade
and the gas ma
y no longer have an odor.
• Propane
gas
can
accum
ulate
at
oor
le
vel.
Smell
near
the
oor
f
or
the
gas
odor
ant
or
an
y
un
usual
odor.Ifyoususpectaleak,donotattempttolight
the pilot.
• Use
caution
when
attempting
to
light
the
propane
pilot.This
should
be
done
b
y
a
qualied
ser
vice
technician,
par
ticularly
if
pilot
outages
are
common.
•
Periodicallychecktheodorantlevelofyourgas.
• Inspectboilerandsystematleastyearlytomake
sureallgaspipingisleak-tight.
• Consult
y
our
propane
supplier
regarding
installation
of
a
gas
leak
detector
.
There
are
some
products
on
the
mar
ket
intended
f
or
this
pur
pose.
Y
our
supplier
ma
y be able to suggest an appropriate device.
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.
Eliminateallsystemleaks.Continualfreshmakeup
waterwillreduceboilerlife.Mineralscanbuildup
in
sections
,
reducing
heat
tr
ansfer,
o
verheating
cast
iron,
andcausingsectionfailure.
Verify water chemistry
Consultlocalwatertreatmentcompaniesforunusuallyhardwater
areas(above7grainshardness)orlowpHwaterconditions(below
7.0).
BoilerwaterpHof7.0to8.5isrecommended.
Freeze protection (when used)
Useantifreezemadeespeciallyforhydronicsystems.Inhibited
propylene glycol is recommended.
Do not use ethylene glycol, automotive or undiluted
antifreeze. Severe personal injury or death can
result.
1
. Determine
antifreez
e
quantity
according
to
system
w
ater
content.
Boiler water content is listed on page 47. Remember
toincludeexpansiontankwatercontent.
2. Followantifreezemanufacturer’sinstructions.
3. A
50%
solution
of
prop
ylene
glycol/w
ater
pro
vides
maxim
um
protection
toabout-30°F.
4. Local
codes
ma
y
require
bac
k
o
w
pre
venter
or
actual
discon
-
nectfromcitywatersupply.
5. When
using
antifreez
e
in
a
system
with
automatic
ll,
install
a
w
ater
meter
to
monitor
w
ater
mak
eup.
Glycol
will
leak
bef
ore
the
w
ater
begins
to
leak,
causing
glycol
le
vel
to
drop
.
Added
w
ater
will
dilute
the
antifreez
e,
reducing
the
freez
e
protection
le
vel.
Preparation
Fill the system with water
1. Closemanualandautomaticairventsandboilerdraincock.
2. Fill
t
o
c
orrect
s
ystem
p
ressure.
C
orrect
p
ressure
w
ill
v
ary
with
each
application.T
ypical
cold
w
ater
ll
pressure
f
or
a
residential system is 12 psi.
3.
Purgeairfromsystem:
a. Connect
ah
ose
t
o
p
urge
v
alve
o
r
v
alves,
i
f
i
nstalled.
R
oute
hose to an area where w
ater can drain and be seen.
b. Close the boiler or system isolation valve between the
purge v
alve and fill connection to the system.
c. Closezoneisolationvalves.
d. Openquick-llvalveoncoldwatermakeupline.
e.
Open purge v
alve.
f. One
z
one
at
a
time
,
open
the
isolation
v
alves.
Allo
w
w
ater
to r
un through the zone, pushing out the air. Run until no
noticeable
a
ir
ow
i
s
p
resent.
C
lose
t
he
z
one
i
solation
v
alves
and
proceed
with
the
ne
xt
z
one.
F
ollow
this
proce
-
dure until all zones are purged.
g. Close
the
quic
k-ll
w
ater
v
alve
and
purge
v
alve
and
remo
ve
the hose
. Open all isolation valves. Watch that system
pressure rises to correct cold-fill pressure.
h. After
the
system
has
oper
ated
f
or
a
while
,
eliminate
an
y
residual air b
y using the manual air vents located through-
out the system.
i. Ifpurgevalvesarenotinstalledinsystem,openmanualair
v
ents in system one at a time, beginning with lowest floor.
Close
v
ent
when
w
ater
squir
ts
out.Repeat
with
remaining
v
ents.
4. Open
automatic
air
v
ent
(diaphr
agm-type
or
b
ladder-type
e
xpansiontanksystemsonly)oneturn.
5.
Open other v
ents:
a.
Star
ting on the lowest floor, open air vents one at a time
untilwatersquirtsout.
b.
Repeat with remaining v
ents.
6. Refill to correct pressure.
Inspect system water piping
Afterlling the boilerand system withwater, inspectallpiping
throughout
the
system
f
or
leaks
.
If
f
ound,
repair
immediately
.
Repeat
this
inspection
after
the
boiler
has
been
star
ted
and
the
system has heated up
.
Leaksmustberepairedatonce.Failuretodosocan
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.
Inspect base insulation
Checktomakesureinsulationissecureagainstallfoursidesof
the
base
.
If
insulation
is
damaged
or
displaced,
do
not
oper
ate
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 dam-
age.
The boiler contains ceramic fiber and fiberglass
materials.Usecarewhenhandlingthesematerials
per
instr
uctions
on
page
48
of
this
man
ual.
F
ailure
to comply could result in severe personal injury.
7 Start-up
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