Union Steam GWA, GWI, GWS User's Information Manual
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Gas-Fired Water Boilers
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User’s Information Manual
Hazard definitions
Hazards that will cause severe personal injury,
death or substantial property damage.
Hazards that can cause severe personal injury,
death or substantial property damage.
Hazards that will or can cause minor personal in-
jury or property damage.
Special instructions on installation, operation or
maintenance that are important but not related to
personal injury or property damage.
The Boiler manual is for use only by a qualified
heating installer/service technician. Refer only to
this User’s Information Manual for your reference.
Improper installation, adjustment, alteration,
service or maintenance can cause property
damage, personal injury (exposure to hazardous
materials) or loss of life. Installation and service
must be performed by a qualified installer, service
agency or the gas supplier (who must read and
follow the supplied instructions before installing,
servicing, or removing this boiler. This boiler
contains materials that have been identified as
carcinogenic, or possibly carcinogenic, to humans).
Propane gas odorant
Propane boilers only — Your propane supplier
mixes an odorant with the propane to make its presence detectable. In some instances, the odorant
can fade and the gas may no longer have an odor.
• Propane gas can accumulate at floor level. Smell near the
floor for the gas odorant or any unusual odor. If you suspect a
leak, do not attempt to light the pilot.
• Use caution when attempting to light the propane pilot. This
should be done by a qualified service technician, particularly
if pilot outages are common.
• Periodically check the odorant level of your gas.
• Inspect boiler and system at least yearly to make sure all gas
piping is leak-tight.
• Consult your propane supplier regarding installation of a gas
leak detector. There are some products on the market intended
for this purpose. Your supplier may be able to suggest an
appropriate device.
INSTALLER — Please take time to review this
User’s Information Manual with the boiler owner.
Explain all maintenance and service procedures
and the correct “Lighting or Operating Instructions”.
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If the information in this manual is not followed exactly, a fire or
explosion may result, causing property damage, personal injury or
loss of life.
Do not store or use gasoline or other flammable vapors and liquids in the
vicinity of this or any other appliance.
• Do not try to light any appliance.
• Do not touch any electrical 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.
Installation and service must be performed by a qualified installer, service
technician or the gas supplier.
WHAT TO DO IF YOU SMELL GAS
Part Number 550-110-726/0703
GWA/GWI/GWS
Gas-Fired Water Boilers – User’s Information Manual
Please read this page first
Failure to adhere to the guidelines on this page can result in severe
personal injury, death or substantial property damage.
Service and maintenance
1. To avoid electric shock, disconnect electrical supply before
performing maintenance.
2. To avoid severe burns, allow boiler to cool before performing
maintenance.
3. You must maintain the boiler as outlined in the manual and
have the boiler started up and serviced at least annually by a
qualified service technician to ensure boiler/system reliability.
Boiler operation
4. DO NOT block flow of combustion or ventilation air to boiler.
GWS boilers are equipped with a control which will
automatically shut down the boiler should air or vent be
blocked. If vent or air blockage is easily accessible and
removable, remove it. The boiler should attempt to restart
within an hour. If blockage is not obvious or cannot be
removed, have the boiler and system checked by a qualified
service technician.
GWI and GWA boilers are equipped with controls which will
automatically shut down the boiler should the vent be blocked.
Should the boiler shut down due to blockage, the GWI device
will automatically reset, but the GWA device must be reset or
replaced only by a qualified installer/service technician.
5. Should overheating occur or gas supply fail to shut off, do not
turn off or disconnect electrical supply to pump. Instead, shut
off the gas supply at a location external to the appliance.
6. DO NOT use this boiler if any part has been under water.
Immediately call a qualified service technician to inspect the
boiler and to replace any part of the control system and any
gas control that has been under water.
7. Have the building monitored when it is vacant for an extended
period. Safety controls can shut down the boiler at any time.
The loss of heat can result in significant damage due to
freezing.
Boiler water
8. DO NOT use petroleum-based cleaning or sealing compounds
in boiler system. Water seal deterioration will occur, causing
leakage between sections and damage to heating system
components. This can result in substantial property damage.
9. DO NOT use "homemade cures" or "boiler patent medicines".
Serious damage to boiler, personnel and/or property may
result.
10. Continual fresh makeup water will reduce boiler life. Mineral
buildup in sections reduces heat transfer, overheats cast iron,
and causes section failure. Addition of oxygen and other gases
can cause internal corrosion. Leaks in boiler or piping must
be repaired at once to prevent makeup water.
11. DO NOT add cold water to hot boiler. Thermal shock can
cause sections to crack.
Glycol — potential fire hazard —
12. All glycol is flammable when exposed to high temperatures.
If glycol is allowed to accumulate in or around the boiler or
any other potential ignition source, a fire can develop. In order
to prevent potential severe personal injury, death or substantial
property damage from fire and/or structural damage:
• Never store glycol of any kind near the boiler or any potential
ignition source.
• Inspect the boiler and system regularly for leaks. Have any
leaks repaired immediately to prevent possible accumulation
of glycol.
• Never use automotive antifreeze or ethylene glycol in the
system. Using these glycols can lead to hazardous leakage
of glycol in the boiler system.
Air contamination
13. To prevent potential of severe personal injury or death, check
for products or areas listed in table below before installing
boiler. If any of these contaminants are found, do one of the
following:
• Remove contaminants permanently. —
• Isolate boiler and provide outside combustion air. See
applicable codes for further information. —
• For GWS boilers only — Duct combustion air from outside
to the boiler air intake.
or
—
or
—
Products to avoid
Spray cans containing chloro/fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents found in
household laundry rooms
Adhesives used to fasten building products and other similar products
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
2 Part Number 550-110-726/0703
GWA/GWI/GWS
Gas-Fired Water Boilers – User’s Information Manual
To locate Lighting or Operating Instructions:
Find your boiler model number on boiler nameplate (begins with GWA, GWI or GWS). GWA model number will
include a suffix indicating pilot ignition — “S” for standing pilot or “I” for spark-ignited pilot. Read the valve
manufacturer’s model and name on the boiler gas valve. Locate the correct “Lighting or Operating Instructions”
using the table below. Use only the instructions applying to your boiler model and gas valve. If you are in doubt
which to use, please contact your boiler installer/technician for assistance.
GWA standing pilot
With gas valve:
Honeywell VR8200/8300 4
Robertshaw 7200 5 Robertshaw 7200 7
Page
GWA spark-ignited pilot
With gas valve:
Honeywell VR8204/8304
White-Rodgers 36C or 36E
Page
GWI or GWS spark-ignited pilot
With gas valve:
6
All gas valves 8
Maintain your boiler using this schedule:
Service technician
(covered in Boiler Manual — for use only by a
qualified service technician)
❏
Inspect:
• Reported problems
• Boiler area
• Air openings
• Flue gas vent system
• Pilot and main burner flames
• Water piping
• Boiler heating surfaces
• Burners, base and inlet air box
• Condensate drain system (GWI and
UP
-
START
NNNUAL
GWS boilers only)
Service:
❏
• Inducer motor (GWI and GWS boilers
only)
• Oiled-bearing circulators
❏
Start-up:
• Perform start-up per manual
A
Check/test:
❏
• Gas piping
• Cold fill and operating pressures
• Air vents and air elimination
• Limit controls and cutoffs
• Expansion tank
• Boiler relief valve
❏ Daily • Check boiler area
❏ Monthly • Check boiler piping
❏ Periodically • Test low water cutoff (if used)
❏ Every 6 months • Operate relief valve
❏ End of season • Shut down procedure
Owner maintenance
(see pages 9 – 11 for instructions)
• Check boiler pressure/
temperature gauge
• Check air openings
• Check venting system
• Check condensate drain system
(GWI and GWS boilers only)
• Check boiler relief valve
• Check automatic air vents (if
used)
• Check pilot and main burner
flames
• Check and clean vent termination
& air intake screens — GWS boilers only
• Oil inducer motor (GWI and GWS
boilers only)
Page
Review:
❏
• Review with owner
3Part Number 550-110-726/0703
GWA/GWI/GWS
Gas-Fired Water Boilers – User’s Information Manual
Lighting Instructions
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.
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.
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any phone in
your building.
LIGHTING INSTRUCTIONS
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.
WHAT TO DO IF YOU SMELL GAS
GWA — Standing pilot
Gas valve — Honeywell VR8200/VR8300
• 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.
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. Turn gas control knob clockwise
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.
to OFF.
TO TURN OFF GAS TO THE APPLIANCE
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. Turn gas control knob counterclockwise
to PILOT.
12. Push in red reset button and hold. Immediately light the
pilot with a match. Continue to hold reset button in for about
one (1) minute after the pilot is lit.
13. Release reset button. Pilot should remain lit. If pilot goes
out, repeat steps 6 through 13.
• If reset button stays depressed after release, stop and
immediately call your service technician or gas supplier.
• If the pilot will not stay lit after several tries, turn the gas
control knob clockwise
technician or gas supplier.
14. Replace access panel.
15. Turn gas control knob counterclockwise
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 OFF and call your service
to ON.
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if service is to
be performed.
4 Part Number 550-110-726/0703
3. Remove front panel.
4. Turn gas control knob clockwise
5. Replace front panel.
to OFF.
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