GT INSTALLATION AND OPERATION INSTRUCTIONS
Page 31
Heat Exchanger Cleaning
Natural Gas - once every two years.
Propane - once per year.
The burner door should be removed so the combustion
chamber can be inspected for flue gas blockage,
see BURNER REMOVAL & REPLACEMENT below.
Once the burner has been removed remove the heat
exchanger baffle. Blockage of the heat exchanger
will reduce the boiler’s capacity/firing rate and can
negatively impact on how smooth and efficiently the
burner lights. Vacuum out any loose build-up and clean
the heat exchanger surface with an appropriate cleaner
for combustion chambers such as Sotin 300. Use a
nylon or other non-metallic brush to loosen the sulfate
incrustations and any other contaminates. Rinse with
water allowing the solution to exit via the condensate
drain. This process may warrant removing the insulation
disc from the back of the heat exchanger.
Heat Exchanger Flushing
Listen for water fl ow noises that indicate a drop in the
boiler water fl ow rate. The boiler and hydronic system
may need to be fl ushed to eliminate hard water scale. A
de-scalar such as Fernox DS-40 is recommend.
Burner Removal & Replacement
WARNING: The ceramic door disc on the rear
of the burner contains crystalline silica. Wear
proper respiration protection when servicing
the burner and gently handle the burner and
its disc to prevent inhalation of airborne fi bers.
Crystalline silica fi bers have been identifi ed as
carcinogenic, or possibly carcinogenic when
inhaled.
CAUTION: The burner should not be removed unless
there is a problem with it. Careless handling can
damage the burner!
1. Close the manual shutoff valve in the gas supply line
and turn off electrical power to the boiler.
2. Remove the front and left jacket panels.
3. Disconnect the wires going to the igniter, fl ame rod,
ground rod, blower and gas valve.
4. Carefully disconnect the gas piping at the union,
Figure 27.
5. Carefully disconnect the air inlet piping at the valve,
Figure 2.
6. Remove the nuts used to attach the burner to the
heat exchanger.
7. Carefully slide the burner out of the unit.
8. Inspect the bur ner for damage or signs of
deterioration. Use a brush or vacuum cleaner
to remove any debris from the burner ports.
9. DO NOT install a damaged or badly corroded burner,
replace it.
10. Inspect the ceramic burner disc for signs of damage
or deterioration and replace it if necessary.
11. Inspect the burner door gasket for signs of damage
or deterioration and replace it if necessary.
12. Inspect the ignition components for signs of damage
or deterioration and replace them if necessary.
13. Reassemble the unit following the removal steps in
reverse order.
14. All gas connections MUST be leak tested before
putting the boiler into operation.
WARNING: Never use an open fl ame to test for
gas leaks. Always use an approved leak detection
method. Failure to comply with this WARNING
could result in an explosion!
15. Confi rm proper operation of the boiler and replace
the jacket panels.
Condensate System
Ensure that the condensate removal system is clean,
sound and working properly.
Vent System
The entire vent system must be thoroughly inspected
for any signs of blockage, damage or leaks. Immediately
replace any unsound vent system piping. Remove any
foreign matter in or near the vent and air inlet terminals
that might obstruct them.
Low Water Cutoff
If the system has been equipped with a low water cut-off
device, follow the manufacturer’s instructions for cleaning
and to confi rm proper operation
Relief Valve
The relief valve should vent water when the test lever is
lifted. It should not weep or discharge water at normal
system pressure. NEVER try to clean or repair the relief
valve! If the valve fails replace it!
Aquastat High Limit
The aquastat high limit controls the maximum water
temperature in the boiler. If the water temperature
reaches the set temperature before the demand for heat
has been met, the aquastat high limit should shut the
burners off. The outlet water temperature should never
exceed
220°F
,
104°C
. If the aquastat high limit fails to
function properly replace it.
Summary of Contents for GT-150
Page 19: ...GT INSTALLATION AND OPERATION INSTRUCTIONS Page 19 Figure 30 Multiple 4 Wire Zone Valves...
Page 22: ...GT INSTALLATION AND OPERATION INSTRUCTIONS Page 22 Figure 33 Boiler Ladder Diagram...
Page 23: ...GT INSTALLATION AND OPERATION INSTRUCTIONS Page 23 Figure 34 Boiler Connection Diagram...
Page 40: ...WESTCAST INC 260 NORTH ELM STREET WESTFIELD MA 01085 TEL 413 562 9631 FAX 413 562 3799...
