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Part Number 550-142-785/0812
GWI
Series 2 Gas-Fired Water Boilers – Boiler Manual
11 Service and maintenance continued
Inducer motor
1. With boiler power OFF,placeafewdropsofS.A.E.20motor
oilineachofthetwomotoroilingcups.
Use only S.A.E. 20 motor oil to lubricate inducer
motor.Donotuseuniversalhouseholdoils.Motor
could be damaged, resulting possible severe prop-
erty damage.
Oiled-bearing circulators
1. ThecirculatorshippedwiththeGWIboileriswater-lubricated.
Nooilingisrequired.
2. Checkother circulators in the system. Oil any circulators
requiringoil,followingcirculatormanufacturer’sinstructions.
Over-oiling will damage the circulator.
Temperature sensor
1. The temperature sensor may accumulate deposits on the
probesurface.Annualinspectionandcleaningoftheprobe
willimproveboilerperformance.
Disconnectpower,unplugharnessfromsensor.
a. Drain boiler water to a level below the sensor.
b. Removesensorfromboiler.
c. Wipeanybuiltupcontaminatesfromprobeandinsulator
surfaces.
d. Reinstall sensor into boiler.
❏ Service
❏ Start-up
1. Perform start-up procedures of Section 7, pages 18–20,
includingproceduretoverifyoperationofburnersonpage20.
2. Verifycoldllpressureiscorrectandthatllsystemisworking
properly.
3. Verifyantifreezelevel(ifused) isatthe rightconcentration
and that inhibitor level is correct.
4. Checkgaspiping,permanualSections 5 and 7,verifyingno
indicationsofleakageandallpipingandconnectionsarein
good condition.
5. Readthe“Operatinginstructions”(page 26).
6. Starttheboilerfollowingthe“Operatinginstructions”(page 26).
❏ Check/test
Gas piping
1. Sniffnearoorandaroundboilerareaforanyindicationofa
gasleak.
2. Test gas piping using bubble test, per Section 5, page 16of
thismanual,ifthereisanyindicationofaleak.
Cold fill and operating pressures
1. While the system is cold, note the pressure reading on the
boilerpressure/temperaturegauge.Verifythatcoldllpressure
is correct.
2. Watch the pressure as the boiler and system heat up to en-
sure pressure rise is normal. Too high a rise would indicate a
waterloggedorundersizedexpansiontank.
Air vents and air elimination
1. Inspectautomaticairvents(ifused).Alsoinspectairsepara-
tors to ensure they are operational.
2. The cap must be unscrewed one turn to allow air to escape.
3. Iftheairventisleaking,removecapandbrieypushvalve
— then release to clean the valve seat.
4. Replace cap by twisting all the way onto valve and then un-
screwing one turn.
Limit controls and cutoffs
1. Inspectandtesttheboilerlimitcontrol.Verifyoperationbyturn-
ing control set point below boiler temperature. Boiler should
cycleoff.Returndialtooriginalsetting.
2. Inspectandtestadditionallimitcontrolsorlowwatercutoffs
installed on system.
Expansion tank
1. Expansiontanksprovidespaceforwatertomoveinanoutas
theheatingsystemwaterexpandsduetotemperatureincrease
orcontractsasthewatercools.Tanksmaybeopen,closed
or diaphragm or bladder type. See Section 4, page 13ofthis
manualforsuggestedlocations ofexpansiontanksandair
eliminators.
Open-type — located above highest radiator or baseboard
unit, usually in the attic or closet. Has a gauge glass and
overflow pipe to a drain.
Closed-type — welded gas tight and located above boiler.
Tankis partiallylledwithwater,leavinganair cushionfor
expansion.
• Makesure this type of tank is tted with a tank tting,
suchastheB>ank-TrolorTacoTaco-Trol.Thistting
reduces gravity circulation of air-saturated tank water
backtothesystemandpreventstheairfrombubblingup
throughthewaterasitreturnsfromthesystem.
• Donotuseautomaticairventsinsystemswithclosed-
typetanks.Theairwillescapefromthesysteminsteadof
returningtothetank.Eventually,thetankwillwaterlogand
nolongercontrolpressurization.Theboilerreliefvalvewill
weepfrequently.
Diaphragm- or bladder-type — welded gas tight with a rub-
bermembranetoseparatethetankpressurizingairandthe
water.Maybelocatedatanypointinthesystem,butmost
oftenfoundneartheboiler.
• Systemswiththistypeofexpansiontankrequireatleast
oneautomaticairvent,preferablylocatedontopofanair
eliminator,asshowninexamplesinmanualSection 4,
page 13.
2. Ifreliefvalvehastendedtoweepfrequently,theexpansion
tankmaybewaterloggedorundersized.
Closed-type tank—tank ismostlikelywaterlogged.Install
atankttingifnotalreadyinstalled.Thenchecklllevelper
ttingmanufacturer’sinstructions.Ifllleveliscorrect,check
tanksizeagainstmanufacturer’sinstructions.Replacewitha
largertankifnecessary.
Diaphragm-orbladder-type—rst,checktanksizetobesure
itislargeenoughforthesystem.Ifsizeistoosmall,addad-
ditionaltank(s)asnecessarytoprovidesufcientexpansion.If
tanksizeislargeenough,removetankfromsystemandcheck
chargepressure(usually12psigforresidentialapplications).
Iftankwon’tholdpressure,membranehasbeendamaged.
Replacetank.
❏ Check/test
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