Smith Cast Iron Boilers GT Series Boiler Checking & Adjustment, Input Rate, Main Burner Flame

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GT INSTALLATION AND OPERATION INSTRUCTIONS

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BOILER CHECKING & ADJUSTMENT

Input Rate

Gas appliances are rated based on sea level operation with no adjustment required at elevations up to 2000 ft, 610 m. At elevations above 2000 ft, 610 m, input ratings should be reduced by 4% for each 1000 ft, 305 m, above sea level. Check the input rate as follows:

NATURAL GAS:

1.Turn off all other gas appliances that use the same gas meter as the boiler.

2.Call the gas company for the gas heating value.

3.Start the boiler and let it run for 15 minutes.

4.Using the gas meter and a stopwatch, clock the time that it takes to burn 10 cubic feet of gas and divide the time by 10.

5.Insert the heating value and the time, in seconds, into the formula below.

Input Rate = Heating Value(Btu/ft3)(3600 s/hr) Flow Rate(s/ft3)

EXAMPLE: If the heating value = 1000 Btu/ft3 and the flow rate = 18 s/ft3

Input Rate = (1000 Btu/ft3)(3600 s/hr) 18 s/ft3

Input Rate = 200,000 Btu/hr

If the computed rate deviates by more than 5% from the rated input value of the unit adjust the gas valve pressure according to the GAS PRESSURE ADJUSTMENT instructions that follow.

PROPANE GAS:

The input rate for LP units is factory set based on the orifi ce size. Use the factory supplied kit to convert the boiler to LP. A combusiton analyzer must be used to ensure that the CO2 reading falls between 9% and 10.5% with a CO reading of less than 175 ppm air free.

CAUTION: Never increase the input to the boiler above that for which it is rated. Doing so can cause premature failure of the boiler!

Gas Pressure Adjustment

Optimum results are obtained when the boiler is operated at its full input rating. If adjustment is necessary the following steps must be followed:

1.Connect a flue gas analyzer to the vent pipe.

2.Rotate the input adjustment screw clockwise to decrease the manifold pressure, counterclockwise to increase it, Figure 41 or 42. The input screw on the GT-150 & 200 is a multi turn needle valve. From fully open to fully closed is approximately 17 turns. A typical adjustment is 0 to 1 turn for natural gas, 0 to 3 turns for LP. The input screw on the GT-400 turns a geared ball valve with a 4 to 1 ratio.Two turns will take the valve from fully open to fully closed. 0 to 1/4 turn is a typical adjustment. Never force the input adjustment screw or the gas valve will be damaged!

3.For natural gas the CO2 reading should fall between 8% and 9.5% with a CO reading of less than 175 ppm air free. For LP gas the CO2 reading should fall between 9% and 10.5% with a CO reading of less than 175 ppm air free.

Main Burner Flame

A properly adjusted main burner fl ame will produce a tight blue fl ame pattern about 1/2 in, 13 mm, tall from the burner’s surface, Figure 44. A yellow fl oating or tall stringy flame is not normal and must be corrected.

WARNING:Yellow, floating flames indicate a lack of combustion air. DO NOT operate the boiler until the problem is solved or severe personal injury or death may occur!

Figure 44 - Burner Flame

Thermostat Adjustment

Set the heat anticipator to 1.1 amps when controlling the boiler directly. For zoned systems set the heat anticipator to match the amp draw of the zone valves or pump relays.

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Contents North ELM Street WESTFIELD, MA 01085 TEL 562-9631 FAX 413 Gama Energy StarContents Before YOU StartBoiler Ratings & Capacities Input vs Elevation Graph Boiler LocationGeneral Venting Guidelines Combustion AIRHorizontal Direct Vent Systems Horizontal Terminal Locations Separate Air Intake and Vent TerminalsWall Penetration Detail External Air Intake and Vent Systems Vertical Direct Vent Systems Debris Screen InstallationConcentric Through the Roof Condensate DrainGeneral Plumbing Guidelines Relief Valve Piping Pressure Relief ValvePrimary Loop Plumbing Multiple Boiler Primary LoopSecondary Loop Plumbing Low Water Cut Off, LwcoSingle Boiler with Indirect Hot Water Heater Multiple Boiler Installation Multiple Zones Using Circulators Multiple Zones Valves with Bypass Valve Equivalent Pipe Length Chart GAS Supply PipingGas Pipe Capacity Thermostat Installation Electrical WiringMultiple Zones w/ Taco Valve Controller Models ZVC403 to ZVC Multiple 4 Wire Zone Valves GT Installation and Operation Instructions GT Installation and Operation Instructions Boiler Ladder Diagram Boiler Connection Diagram Boiler Modulation Sentry 2100T ControllerIndirect Water Heaters Sentry DisplayRecommended Settings Setting Sentry 2100T controlRecommend System Temperatures Outdoor Sensor 10KDetermining Reset Temperature HICalc = 200F, 93C 70F, 21C /70F, 21C=140.6 F, 42C Boiler SET UP Operating InstructionsNormal Flue Gas Composition Natural Gas Propane Ignition System Gas Valve Layout, GT-150Operational Flow Chart For Your Safety Read Before Operating Gas Pressure Adjustment Boiler Checking & AdjustmentInput Rate Main Burner FlameBoiler Maintenance Aquastat High Limit Wall Hung ConversionTemperature is Trouble ShootingBurner shuts off Before set-pointAir Switch is Closed Air Switch is OpenIndicates that Ignition SequenceFenwal Two Flashes onThree Flashes on Boiler will not stayHousing Creating a noise Residence. This is not a warranty issueWarranty issue Sentry ControllerGT Installation and Operation Instructions Replacement Parts Exploded View Models GT150 and GT200 Replacement Parts ListReplacement Parts Exploded View Model GT400 GT Installation and Operation Instructions WESTCAST, INC

GT Series specifications

Smith Cast Iron Boilers GT Series has become a benchmark in the hydronic heating industry, renowned for its exceptional performance, durability, and efficiency. This series is designed to cater to diverse heating needs, making it a popular choice among both residential and commercial applications.

One of the standout features of the GT Series is its robust cast iron construction. The cast iron sections offer superior thermal mass, allowing for better heat retention and distribution. This characteristic ensures that the boiler operates efficiently, maintaining comfortable temperatures even during extreme cold weather conditions. The engineers at Smith have meticulously designed each section to provide maximum strength and longevity, resulting in a boiler that can withstand the test of time.

The GT Series also incorporates advanced combustion technology. It utilizes a high-efficiency burner that optimizes fuel consumption, resulting in lower operating costs for homeowners and businesses alike. The boiler is engineered to accommodate a variety of fuel types, including natural gas and propane, giving users flexibility in their energy choices. This adaptability not only enhances efficiency but also promotes environmental sustainability by allowing for the use of cleaner fuel sources.

Another notable technology featured in the GT Series is the electronic control system. This system simplifies boiler operation and enhances user convenience. The intuitive interface provides real-time feedback and diagnostics, making it easier for technicians to perform maintenance and troubleshoot any issues that may arise. Additionally, the boiler’s modulating operation adjusts the burner output according to the heating demand, further improving efficiency and comfort.

Moreover, the GT Series is designed with user-friendly installation in mind. Its compact footprint allows for easy integration into existing heating systems, minimizing space requirements. Additionally, the boiler is equipped with convenient access points for maintenance, ensuring that servicing is straightforward and can be performed without extensive downtime.

Lastly, the Smith Cast Iron Boilers GT Series is designed to meet stringent safety and performance standards. Featuring multiple safety controls and systems, it provides peace of mind for users. With a commitment to quality, efficiency, and performance, the GT Series stands out as a leading solution for hydronic heating, catering to the evolving needs of today’s energy-conscious consumers.
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