Boiler Maintenance - Smith Cast Iron Boilers GB100W Installation & Operating Instructions Manual

Page 24
If the computed rate deviates by more than 5% from the
rated input value of the unit adjust the gas valve
pressure accordingly. DO NOT adjust the manifold
pressure by more than 5%. If a proper rate cannot be
maintained without adjusting the manifold pressure
beyond the 5% limit, the main burner orifices must be
replaced. If the input rate is too low, go to the next lager
size orifices. If the input rate is too high, go to the next
smaller size.
CAUTION: Never increase the input to the boiler
above that for which it is rated. Doing so can cause
premature failure of the boiler!
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!
Low Water Cutoff
If the boiler is equipped with a low water cutoff device
make sure that the main burners will NOT light when the
boiler has no water in it. To check, turn the boiler off,
close the valves in the water supply and return lines and
drain the boiler. If the boiler's main burners light shut the
boiler off immediately and correct the problem.
Thermostat Adjustment
For a thermostat that employs an adjustable heat
anticipator, adjust the anticipator to match the current
measured in the thermostat circuit. An increased
anticipator setting may be necessary if the unit cycles
frequently. If the room temperature over-shoots the
thermostat setting, reduce the anticipator setting.

BOILER MAINTENANCE

WARNING: The ceramic combustion chamber in
the burner box and its gasket contain crystalline
silica. Wear a tightly fitted dust mask when
servicing the burner and gently handle the burner
and its gasket to prevent inhalation of airborne
fibers. Crystalline silica fibers have been identified
as carcinogenic, or possibly carcinogenic when
inhaled.
CAUTION: Servicing, inspection and adjustment
must be done by a trained technician in accordance
with all applicable local and national codes. Verify
proper operation after servicing. Improper servicing
or adjustment can damage the boiler!
The boiler should be cleaned and inspected once a
year, before each heating season. Make sure that the
burners and ignition components are free from dust,
soot, dirt, corrosion or other deposits that would impair
the boiler's performance. Refer to Replacement Parts
page for component identification.
GB100W NATURAL OR PROPANE BOILER
INSTALLATION AND OPERATING INSTRUCTIONS
Burner Removal
1. Close the manual shutoff valve in the gas supply
line and turn off electrical power to the boiler.
2. Disconnect the boiler ground joint union, see
Figure 12.
3. Remove the front access panel.
4. Where applicable, disconnect the wires, pilot tube
and thermocouple from the gas valve.
5. Remove the two nuts that retain the manifold
assembly and remove the assembly.
6. The burner support panel has two jacket screws in
it. Remove the screws to free the support panel and
burners.
Burner Installation
1. DO NOT install damaged or badly corroded
burners - replace them.
2. Insert the crimped end of each burner into the
burner base rear panel slots. Carefully slide the
burner support panel over the burner tubes and
studs.
3. Work the manifold assembly into position and
reattach it using the two nuts.
4. Replace the two jacket screws and reconnect all
wires, tubing and anything else that was
disconnected during the burner removal operation.
5. Complete the reassembly and follow the
instructions in the BOILER OPERATION section
of this manual.
Heat Exchanger Cleaning
The burners should be removed to protect them from
falling rust and scale. Follow the Burner Removal
instructions in this manual.
1. Disconnect the vent pipe and the stack damper.
2. Remove the front access and top panels.
3. Disconnect the spill switch wires.
4. Remove the two screws from the flue collector
retaining clips. Separate the flue collector from the
heat exchanger.
5. Remove the flue collector.
6. Remove as much of the old flue collector sealant as
possible. Thoroughly clean the flue passages with a
wire brush.
7. Vacuum out the burner base and clean and
inspect all of the components. Replace any
damaged or badly corroded parts.
8. Reseal the flue collector using Dow Corning #732 or
an equivalent sealant. And install the flue collector
retaining clips and screws.
WARNING: Failure to properly seal the flue
collector to the heat exchanger can result in
leakage of combustion products which can
result in severe personal injury or death!
9. Replace the top panel and reconnect the spill switch
wires and vent system.
10. Follow the Burner Installation procedure
outline in this section.