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 injury 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 boilers only ??? Your propane supplier mixes an odorant with the propane to make its pres- ence 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 Instructions???.

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.

Air contamination

12.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. ??? or ???

???Isolate boiler and provide outside combustion air. See applicable codes for further information.

Boiler operation

4.DO NOT block flow of combustion or ventilation air to boiler. GSA 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, these devices 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.

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

Service technician

(covered in Boiler Manual ??? for use only by a qualified service technician)

???Check venting system

???Check/operate boiler relief valve

???Check pilot and main burner flames

???Periodically ??? Test low water cutoff

???End of season ??? Shut down procedure

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.

???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.

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 clockwiseto 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.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

14.Replace access panel.

15.Turn gas control knob counterclockwiseto 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.

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.Turn gas control knob clockwiseto OFF.

5.Replace front panel.

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.

???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.

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 leftto 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

14.Replace access panel.

15.Turn selector arm leftto 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.

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 leftto OFF.

5.Replace front panel.

Maintenance procedures

The boiler should be inspected and started annually, at the beginning of the heating season, only by a qualified service technician. In addition, the maintenance and care

of the boiler designated on page 3 and explained on the following pages must be performed to assure maximum boiler efficiency and reliability.Failure to service and maintain the boiler and system could result in equipment failure, causing possible severe personal injury, death or substantial property damage.

The following information provides detailed instructions for completing the maintenance items

listed in ???Maintain your boiler using this schedule??? on page 3. In addition to this maintenance, the boiler must be serviced and started up at the beginning of each heating season by a qualified service technician.

See page 8 for ???Troubleshooting??? procedures for common problems.

Component information

Rollout thermal fuse element

The Rollout TFE is located above the burners. It cuts off gas flow should flame rollout occur.

Do not attempt to place boiler in operation if rollout

thermal fuse element cuts off gas flow. Immediately call a service technician.Failure to do so can cause severe personal injury, death or substantial property damage.

Spill switch

The Spill switch is attached to the draft diverter. It cuts off gas flow if the vent system becomes blocked.

Do not attempt to place boiler in operation if spill

switch cuts off gas flow. Immediately call a service technician. Failure to do so can cause severe personal injury, death or substantial property damage.

??? Check daily

Boiler area

To prevent potential of severe personal injury, death or substantiaW-T

8201 W. Calumet Rd.

Milwaukee, WI 53223l property damage, eliminate all materials discussed below from the boiler vicinity. If found:

???Remove products immediately from the area. If they have been there for an extended period, call a qualified service technician to inspect the boiler and vent system for possible damage from acid corrosion.

???If products cannot be removed, immediately call a qualified service technician to install an outside combustion air source for the boiler (if not already installed).

1.Combustible/flammable materials ??? Do not store combustible materials, gasoline or any other flammable vapors or liquids near the boiler. Remove immediately if found.

2.Air contaminants ??? See listing of contaminants on page 2.

Pressure gauge

1.Make sure the pressure reading on the boiler pressure gauge does not exceed 15 psig. Normal operation is usually less than 5 psig. At certain times the system may be under vacuum conditions.

2.Contact a qualified service technician if problem persists.

Air openings

1.Verify that combustion and ventilation air openings to the boiler room and/or building are open and unobstructed.

??? Check monthly

Boiler and system piping

1.Visually inspect for leaks around piping, relief valve and other fittings. Immediately call a qualified service technician to repair any leaks.

Have leaks fixed at once by a qualified service technician. Continual fresh makeup water will reduce

boiler life. Minerals can build up in sections, reducing heat transfer, overheating cast iron, and causing section failure.

Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to boiler

and system components can occur, resulting in possible severe personal injury, death or substantial property damage.

Venting system

1.Visually inspect all parts or the flue gas venting system for any signs of blockage, leakage or joints or deterioration of the piping.

2.Check vent system operation:

a.With boiler firing, hold a candle or match below lower edge of draft diverter ???skirt.??? If flame does not blow out, but burns undisturbed, the vent system is working properly. If flame blows out or flickers severely, the vent system must be checked for obstructions or other causes of improper venting.

b.Verify the vent damper opens before burners ignite.

3.Notify your qualified service technician at once if you find any problem.

Failure to inspect the vent system as noted above and have it repaired by a qualified service technician can result in vent system failure, causing severe

personal injury or death.

Boiler relief valve

1. After following the warning directions below, if the relief valve weeps or will

not seat properly, replace the relief valve.

Before testing, make certain discharge pipe is properly

connected to valve outlet and arranged to

contain and safely dispose of boiler discharge. Wear gloves to protect your

hands from hot surfaces. Verify that

discharge piping is installed in accordance with this manual and the instructions on the relief valve tag. Failure to comply will expose operator and others to severe personal injury or death.

Safety relief valves should be reinspected AT LEAST ONCE EVERY THREE YEARS, by a licensed plumbing contractor or authorized inspection agency, to ensure that

the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally.Certain naturally occurring conditions may corrode the valve or its components over time, rendering the valve inoperative. Such conditions are not detectable unless the valve and its components are physically removed and inspected. This inspection must only be conducted by a plumbing contractor or authorized inspection agency ??? not by the owner. Failure to reinspect the boiler relief valve as directed could result in unsafe pressure buildup, which can result in severe personal injury, death or substantial property damage.

Check the setting of the boiler limit control.The control should never be set with a pressure above

10 psig. Operating at a higher pressure can cause damage to the boiler relief valve.

The boiler relief valve must be tested at least monthly during the heating season to verify the valve

and discharge piping flow freely. If corrosion and/or deposits are noticed within the valve body, testing must be performed more often. A ???try lever test??? must also be performed at the end of any non- service period. Follow the instructions below for a ???try lever test???.

???With the system at operating pressure, lift and hold the test lever fully open for at least 5 seconds to flush the valve seat free of sediment and debris.Then release lever and permit the valve to snap shut.

Pilot burner flame

Proper pilot flame (see right):

1. Blue flame.

2. Inner cone engulfing thermocouple.

3. Thermocouple glowing cherry red.

Improper pilot flame:

1.Overfired ??? Large flame lifting or blowing past thermocouple.

2.Underfired ??? Small flame. Inner cone not engulfing thermocouple.

3.Lack of primary air ??? Yellow flame tip.

4.Incorrectly heated thermocouple.

Main burner flame

Proper main burner flame (see right):

1.Yellow-orange streaks may appear (caused by dust).

Improper main burner flame:

1.Overfired ??? Large flames.

2.Underfired ??? Small flames.

3.Lack of primary air ??? Yellow tipping on flames (sooting will occur).

??? Periodically

Test low water cutoff

Probe-type low water cutoff (see right)

Check probe-type low water cutoff for proper operation.

1. Turn off power to boiler and wait 5 minutes.

2.Drain water to bottom of gauge glass.

3. Turn on power.

4. Set thermostat to call for heat. Red neon lamp on lower water cutoff should light.

5.Wait 5 minutes. Boiler should not fire.

6.Refill boiler to correct water line. Red lamp should go off.

7.Wait 5 minutes. Boiler should fire.

8.Return thermostat to normal setting.

Float-type low water cutoff (by others, if used)

1.Blowdown control and test per control manufacturer???s instructions.

Scald potential. Do not blowdown low water cutoff unless blowdown piping has been installed according to control manufacturer???s instructions. If piping is not installed, call

a qualified service technician.

Shutdown procedure

1.Follow ???TO TURN OFF GAS TO APPLIANCE??? on the "Lighting Instructions" on the inside of the jacket panel.You will also find these instructions on pages 4 and 5 of this manual.

Use the "Lighting Instructions" for the gas valve model installed on the boiler.

2.Do not drain system unless exposure to freezing temperatures will occur.

3.Do not drain the system if it is filled with an antifreeze solution.

4.Do not shut down boilers used for domestic water heating.They must operate year-round.