Smith Cast Iron Boilers GB200 SERIES manual 15

3. Bad thermostat.

CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

Verify proper operation after servicing.

Overheating

1. Wrong thermostat anticipator setting.

2. Bad thermostat location.

Noise

1. Ignition or ignition noise due to incorrect air shutter adjustment.

2. Whistle due to burr on orifices.

3. Burner "fluteings" due to air shutter opening too wide.

1. Unit overfired.

2. Air shutter misadjust- ment.

3. Wrong orifices.

4. Burning in burner mix- ing tube.

1. Leak in piping.

2. Carbon build-up in flueways.

3. Blocked chimney.

Carbon Build-Up

Moisture In Building

Yellow Flame,

Odor, Excessive

1. Incorrect thermostat anticipator setting.

2. Low pressuretol setting.

3. Boiler undersized or underfired.

4. Insufficient radiation.

1. Blown fuse or circuit breaker.

2. Switch turned off.

3. Pilot outage

4. IID system malfunction.

5. Flue damper not open.

6. Water level too low.

4. All orifices are screwed into the manifold and may be removed by using a 5/8" wrench or socket.

5. Reverse procedures above to install orifices and burners.

Be sure to reinstall burners with burner ports on the top surface (upright).

HEATING SYSTEM PROBLEMS & CAUSES

No HeatInsufficient Heat

4.Check gas manifold for proper position and reassemble burners to the manifold. Line up holes in burners with the ori- fices, and slide assembly back into position. Be sure to rein- stall burners with burner ports on the top surface (upright).

5.When a low water cut-off has been utilized, follow the manufacturer’s maintenance instructions. As a minimum, test the operation of electronic controls at least once a year. Remove, clean and inspect the probe. Float type controls should be flushed once a month during the heating season. If LWCO fails to operate properly; it must be replaced.

6.Follow "System Start-Up & Adjustments" procedures in Section 3 of this manual.

STEAM BOILER CLEANING INSTRUCTIONS

The following procedures must be followed on initial start-up and if the presence of sediment, sludge or impurities hamper proper boiler operations.

1.With gate valves closed on supply and return lines, start burner and allow boiler to become pressurized so that the pres- suretol may be adjusted and set for limit cut-off desired (nor- mally about 3 psi). Turn off burner and allow pressure to drop to

0psi., then proceed with the following cleaning procedure.

2.Remove the pressure relief valve.

3.Add caustic soda (lewis lye) through this opening at the rate of one pound per thousand square feet of radiation capacity. Scout, Squirk or similar steam boiler cleaners may be used instead of lye. Trisodium phosphate (1/4#) is also an excellent cleaner.

4.Provide pipe connection (full size) from pressure relief valve opening to a convenient drain to serve as a vent.

5.Fill the boiler with a manual fill valve until water starts to trickle from this pipe.

6.Fire boiler at sufficient rate to generate and maintain steam. Entrain water and impurities will then discharge (with steam) from open vent. Add water as necessary so that the low water cutoff does not shut off burner.

7.Continue this process for a minimum of one hour. The process should continue until the steam is dry (no water coming from the vent when the water in the gauge glass is at a normal level, approximately 2/3 full). The time required could vary up to 3 hours.

8.Turn gas valve to off position. While boiler is still hot, drain completely through boiler drain. Make sure that all low points in the return line are also completely drained. These areas could trap chemicals and dirt.

9.Close boiler drain and refill with clean untreated warm water. If warm water is not used, fill very slowly so as not to crack boiler sections. Fill until water overflows through vent pipe and runs clear.

10.Completely drain boiler again.Refill with clean untreated water to normal level.

11.Remove vent drain piping and reinstall pressure relief valve. Open gate valves on supply and return lines. Turn on burner. System is now ready to operate.

HOW TO CHANGE ORIFICES

1.Shut off power supply and gas supply to the boiler.

2.Remove burner access panel. Lift burners up and to rear until burners are disengaged from orifices.

3.Check orifices for proper drill size. Size is stamped onto the body of the brass orifice (see Figure 4.1). Size can also be checked by using a pin gauge.

FIGURE 4.1: GB200 ORIFICE SIZES

Boiler	GB200-3	GB200-4L	GB200-4H	GB200-5
Model
(1) Nat. Gas	41	41	37	38
Drill Size
(2) Prop. Gas	53	53	52	52
Drill Size

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