Calumet GSA Manual - Start-Up
GSA Gas-Fired Steam Boilers – Boiler Manual
15
Part Number 550-110-738/0703
Check burner flame — Pilot burner
Proper pilot flame (see Figure 12):
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.
Verify operation
2. Underfired — Small flame. Inner cone not engulfing
thermocouple.
3. Lack of primary air — Yellow flame tip.
4. Incorrectly heated thermocouple.
Check burner flames — Main burner
Proper main burner flame (see Figure 13):
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).
Figure 13
Typical main
burner flame
Figure 12
Typical pilot
burner flame
Operate boiler
continued
Start the boiler
1. Check boiler water level — Should be approximately ½ way up
gauge glass.
2. Remove boiler jacket door and note the gas valve manufacturer
and model number.
3. Follow the “Lighting Instructions” on page 18 or 19, depending
on gas valve installed in boiler. Use only the “Lighting Instruction”
which applies to this gas valve. (The “Lighting Instruction” label
on the boiler provides the same information.)
4. If boiler fails to start, see “If boiler doesn’t start . . . Check for:”
on this page.
Check system and boiler
Eliminate all system leaks. Continual fresh makeup
water will reduce boiler life. Minerals can build up in
sections, reducing heat transfer, overheating cast iron,
and causing section failure.
If you discover evidence of any gas leak, shut down
the boiler at once. Find the leak source with bubble
test and repair immediately. Do not start boiler again
until corrected. Failure to comply could result in
severe personal injury, death or substantial property
damage.
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Severe damage to boiler
will occur, resulting in substantial property damage.
1. Check system piping for leaks. If found, shut down boiler and
repair immediately.
2. Inspect vent system thoroughly for signs of deterioration from
corrosion, physical damage or sagging. Verify that masonry
chimney liners are in good condition, with no obstructions, and
there are no openings into the chimney.
3. Check around the boiler for gas odor following the procedure of
“Check for gas leaks”, page 14.
4. Verify operation using procedures below. Perform “Checkout
procedure”, page 16, and fill in the “Installation and service
certificate”.
If boiler doesn’t start . . . Check for:
1. Loose connections, blown fuse or service switch off?
2. High limit switch set below boiler pressure?
3. Thermostat set below room temperature?
4. Gas not turned on at meter or boiler?
5. Incoming gas pressure less than:
5" w.c. for natural gas? 11" w.c. for propane gas?
6. If none of the above corrects the problem, see “Troubleshooting”,
page 24.
7
Start-up
continued
Check vent damper operation
1. Raise room thermostat to call for heat — Vent damper actuator
will slowly open vent damper.
2. When vent damper is fully open — Main gas valve will open
and main burners will ignite.
Vent damper must be fully open before main burners
light. If vent damper does not fully open, flue products
such as carbon monoxide will escape into house,
causing severe personal injury or death.
3. Lower thermostat setting — Main burner flames will go out, then
vent damper will close.
4. Repeat Steps 2 through 4 several times to verify operation.
5. Return thermostat to normal setting.
6. Set thermostat heat anticipator setting indicated on wiring
diagram.
Check venting system operation
1. 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.