SECTION 3: START-UP & OPERATION

SEQUENCE OF OPERATION

For sequence of operation of the particular boiler being installed, refer to Figures 2.8, 2.9, 2.10 and 2.11 in Section 2 of this manual.

Spill and rollout switches are mounted on all GB200 boilers.

The spill switch detects the escape of combustion products through the draft diverter relief opening and interrupts the power to the gas valve preventing unsafe boiler operation. Escape of flue products could be caused by a blocked or collapsed chimney or inadequate chimney draft. This is a manual reset-type device and can be reactivated by depressing the spill switch reset button mounted on the left of the boiler’s draft diverter (see Figure 2.1 for switch location).

The rollout switch prevents flame rollout from the boiler combustion chamber, caused by blocked boiler flue passage- ways, by interrupting power to the gas valve to prevent unsafe boiler operation. This is a manual reset-type device and can be reactivated by depressing the rollout switch reset button mounted on the lower front jacket panel (see Figure

2.1for switch location). Flue passages must be inspected by a qualified installer if this problem occurs, prior to switch replacement.

WARNING: If boiler cannot be restored to normal operation after re-setting of spill switch, or if flame rollout switch has tripped, do not attempt to put the boiler in operation. Immediately contact a qualified service professional.

PRIOR TO START-UP

Fill system with water until the water level indicator (sight glass) is approximately 2/3 full. This water level is 23" from the surface on which the boiler sits.

SYSTEM START-UP & ADJUSTMENTS

Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in ANSI Z21.13-

LATEST EDITION

WARNING: Keep boiler area clear and free from combustible materials, gasoline and other flammable vapors and liquids. Otherwise fire or explosion may result.

1.Check combination gas valve on boiler and make sure it is in the OFF position.

2.For vent damper-equipped models, with the thermostat set to call for heat, observe that vent damper position indicator rotates to the open position (see Figure 2.5). Damper must be in the open position when appliance main burner is operating.

a. After damper opens, spark should appear at the pilot ignition electrodes.

FIGURE 3.1: STEAM CONTROL ARRANGEMENT

PRESSURE

PRESSURE

RELIEF VALVE

CONTROL

 

PRESSURE

 

GAUGE

 

OPTIONAL

PRESSURE RELIEF

FLOAT

VALVE DISCHARGE

LOW WATER

PIPING

CUT OFF

 

GAS VALVE

b. Set thermostat to no longer call for heat. Spark should stop. Observe that damper position indicator rotates to the closed position.

c. Set thermostat to call for heat.

3.Light the boiler. For Model GB200 boilers with intermit- tent pilot, see lighting instruction on Page 14.

4.Observe pilot and main burner flame (see Figure 3.2). All burner ports should be ignited and burn with a steady blue flame.

CAUTION: Never leave the job with yellow burning flames. This condition indicated poor combustion and will quickly carbonize the boiler, reducing efficiency and boiler life. It may also be an indication of improper venting or combustion air supply. If unable to adjust flame properly, consult your local utility.

5.Boilers are shipped from the factory with the primary air shutters on the main burner wide open. It is recommend- ed these air shutters be left in the wide open position unless there is lifting of the flame above the burner ports. If there is lifting, the air shutters should be gradually closed until the lifting is eliminated. It may also be neces- sary to adjust the primary air shutters if the input rate is reduced by a change in the orifices.

6.After burner has been in operation for about 10 minutes, check gas input rate to boiler as follows:

a.Make sure all appliances served by the meter are turned off during timing of gas input rate to the boiler.

b.Measure the time in seconds that it takes for the boiler to use 10 cubic feet of gas. Divide 36,000 by the number of seconds (this is the number of cubic feet of gas used per hour). Multiply this figure by the heating value of the gas to obtain Btu input per hour.

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