Smith Cast Iron Boilers 19A User Manual

19IOM-5

INSTALLER

READ THESE INSTRUCTIONS CAREFULLY. THEY WILL

SAVE TIME IN ASSEMBLING BOILER

19A SERIES BOILER

INSTALLATION

INSTRUCTIONS

STEAM OR WATER HEATING

PRESSURIZED FOR FIRING OIL, GAS

OR COMBINATION GAS/OIL

DESIGNED AND TESTED ACCORDING TO THE A.S.M.E.

BOILER AND PRESSURE VESSEL CODE, SECTION IV

FOR MAXIMUM ALLOWABLE WORKING PRESSURE.

STEAM - 15 PSIG, WATER - 80 PSIG

CANADA: STEAM - 15 PSIG, WATER - 50 PSIG

CAUTION

Do not use automotive anti-freeze in boiler waterways. If necessary to use antifreeze, be sure to employ a preparation designed for hydronic heating systems such as ethylene or propylene glycol.

Water treatment is not recommended. This boiler uses gaskets to seal the ports of adjoining sections. These gaskets are made of a fluorocarbon elastomer (designation FKM) marketed under the brand name Viton. Consult a water treatment professional before adding any chemical to the boiler water. Any water treatment or anti-freeze added to the system must be compatible with the Viton gaskets.

THE SECTIONS OF THIS BOILER MUST BE ASSEMBLED

TO THE PROPER TORQUE. READ INSTRUCTIONS

THESE INSTRUCTIONS TO BE LEFT WITH THE BOILER FOR REFERENCE PURPOSES

WESTCAST, INC.

260 NORTH ELM STREET WESTFIELD, MA 01085 TEL. [phone] FAX [phone]

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19A SERIES BOILER

INSTALLATION INSTRUCTIONS

8
7
9
6
22
5
2 0
2	3
	1
	1 5
23
24
21
1 7	1 3	1 4	1 1	1 2
1 0
			1 9
1 8
1 6
25

Item	Comp.		Item	Comp.
No.	No.	Description	No.	No.	Description
1	3638	Front Section	—	3640	Burner Mounting Plate,
2	3637	Intermediate Section, Plain			Powerflame - 91/8" Opening
3	3641	Intermediate Section, Heater (Optional)	13	60023	Burner Mounting Plate Rope, 1/4"
4	3639	Back Section	14	60434	Burner Mounting Plate Insulating Block
5	3575	Smokehood 7"	14	60430	Burner Mounting Plate Insulating Block
	3576	Smokehood 8"			(Beckett Burner)
	3577	Smokehood 9"	15	60331	Upper Port Hydronic Seal
	3578	Smokehood 10"	16	60332	Lower Port Hydronic Seal
6	69370	Slide Damper	17	60025	Insulating Ceramic Rope
7	—	Tankless Heater	18	—	Tie Rod & Hardware
		(For Intermediate Heater Sections Only)	19	—	Front Observation Port
8	3572	Heater Cover Plate, Blank	20	70553	Rear Observation Port Assembly
9	60333	Heater Cover Plate Gasket	21	71700	Rear Observation Port Cover Plate -
10	3611	Cleanout Cover Plate			3, 4, 5, 6 Section Boilers
11	3565	Burner Mounting Plate,	22	74300	Insulating Bolt Hole Tape 3' 6"
		Carlin - 6 1/8" Opening	23	74302	Insulating Tape 11"
12	3566	Burner Mounting Plate,	24	69150	Angle Bracket
		Powerflame - 73/4" Opening	25	69761	Target Wall - 3, 4, 5, 6 Section Boilers

PAGE 3

19A SERIES BOILER

INSTALLATION INSTRUCTIONS

TABLE OF CONTENTS

SECTION	DESCRIPTION	PAGE		SECTION	DESCRIPTION	PAGE
	19A SERIES ISOMETRIC DRAWING	2		10	TANKLESS HEATERS	6
	PARTS LIST	2		11	SMOKEHOOD	6
	TABLE OF CONTENTS	3		12	BURNER MOUNTING PLATE	7
1	GENERAL INFORMATION	3		13	CLEANOUT COVERS	8
2	BOILER LOCATION	3		14	REAR OBSERVATION PORT	8
3	CODES AND REGULATIONS	3		15	CONTROL LOCATIONS	8
4	CHIMNEY AND BREECHING	3		16	JACKET	8
5	COMBUSTION AND VENTILATION AIR	4		17	SAFETY AND RELIEF VALVES	8
6	ASSEMBLY OF SECTIONS	4		18	CLEANING BOILER WATERWAYS	9
7	HYDROSTATIC TEST	5		19	OWNER'S INSTRUCTIONS	9
8	STEAM PIPING	5			CONTROL TAPPINGS DIAGRAM	10
9	WATER PIPING	6			WARNING	11

1.GENERAL

19A Series boilers are wet-base, extended surface, vertical flue design with integral cast flue gas collector for pressurized firing with oil, gas or combination power burners. Upper and lower port hydronic seals are of a special material resistant to petroleum products and compatible with ethylene and propylene based anti-freeze (non automotive type) which does not contain corrosion inhibitors to protect aluminum. The flue gas joints between sections, etc. are sealed using high temperature (2300° F) ceramic fiber rope. Access to the heating surface for cleaning is provided from the left hand side of the boiler through large cast iron cover plates. A slide damper is provided in the flue gas outlet for back pressure adjustment.

The boilers are supplied completely knocked down for field assembly, as factory assembled blocks of sections or completely assembled boiler-burner units. All items should be inspected for damage upon receipt, and any damage reported to the wholesaler and trucker. All components should be stored in a clean, dry area.

The boilers are conservatively rated for high efficiency performance with capability for down-firing to match connected load. The large OBROUND upper port provides transfer area above the water surface for dry steaming at full load.

2.BOILER LOCATION

The boiler must be installed on a smooth, level, noncombustible floor or pad as close to the chimney or vent location as possible to minimize breeching length. Allow clearance around the boiler for piping, service, maintenance, cleaning and tankless coil removal. Approximately 30 inches on the sides is a minimum (Check local code requirements). Do not install electrical conductors in floor or pad under boilers.

See FIGURE 1 for boiler floor pad requirements, and TABLE 1 for minimum required pad length.

	TABLE 1
Boiler No.	Min. Recommended Pad Length
19-*-3	30"
19-*-4	36"
19-*-5	42"
19-*-6	48"
19-*-7	54"
19-*-8	60"
19-*-9	66"
19-*-10	72"
19-*-11	78"
19-*-12	84"

3.CODES AND REGULATIONS

All work in connection with the boiler, burner and controls must be performed in strict accordance with requirements of state and local authorities having jurisdiction over boiler installations.

		32"
	JACKET SIDE PANEL
	FLOOR	C OF BOILER
		L
	OR PAD
	1 1/2" x 2 1/2" ANGLES
4 5/32"	12 27/32"	12 27/32"	4 5/32"
		25 21/32"
		34"

FIGURE 1

In the absence of such local requirements, the following should govern:

A.S.M.E. Section IV - “Heating Boilers"

A.S.M.E. Section VI - “Care and Operation of Boilers” ANSI/NFPA 31 - “Installation of Oil Burning Equipment” ANSI/Z223.1 - “National Fuel Gas Code”

ANSI/NFPA 70 - “National Electrical Code”

4.CHIMNEY AND BREECHING

The breeching connection between boiler and chimney should be as direct as possible with the minimum number of elbows or bends. It should pitch upwards to the chimney at a rate of 1/4 inch per foot of horizontal run. Generally, the breeching and chimney should be the same diameter as the boiler outlet connection.

NOTE

11 and 12 section uses adapter collar for connection to 12" diameter vent system.

For fuel conservation and stable burner performance, the vent connection from the boiler should not include a barometric draft control or other opening unless the venting system can develop an excessive draft, or is required by code.

PAGE 4

19A SERIES BOILER

INSTALLATION INSTRUCTIONS

5.COMBUSTION AND VENTILATION AIR

An adequate supply of air for the boiler room must be provided to allow complete combustion of fuel and ventilation of the room to avoid excessively high ambient temperature. Air inlet by natural ventilation directly from the outside shall have total free area of not less than one sq. in. per 14,000 BTU per hour of input of all fuel burning appliances in the boiler room.

Where combustion air must be obtained through ducts, see ANSI/NFPA 31 or ANSI Z223.1 for requirements.

If mechanical combustion air supply is required, the system must be approved by the local authorities, and should provide at least 30 CFM per gallon of oil and 0.25 CFM per MBH of gas input to the boilers.

Ventilation air, if required, must be in addition to the combustion air quantities called for above.

6.ASSEMBLY OF SECTIONS

When boilers are delivered to the job site, each item should be inspected closely for possible shipping damage. Scars or nicks in the port sealing surfaces may allow leakage. Do not attempt to use any section that has been damaged in the port seal area.

When ready to commence assembly, recommended on a level pad, place the angle rails in position parallel with each other with the 2" legs on the floor and measuring 25-21/32 inches outside dimension. Be sure to align the center of the boiler with the center line of the pad. If no pad is provided, shim and grout under the angles to make them level and provide support along the full length. See FIGURE 1. Clean hydronic gasket recesses and rope groove with a wire brush, taking care not to damage machine surface.

See TABLE 2 for proper location of sections.

TABLE 2

3 SECT

F

H

B

4 SECT

F

P

H

B

5 SECT

F

H

P

H

B

6 SECT

F

P

H

P

H

B

7 SECT

F

H

P

H

P

H

B

8 SECT

F

P

H

P

H

P

H

B

9 SECT

F

P

H

P

H

P

H

P

B

10 SECT

F

P

P

H

P

H

P

H

P

B

11 SECT

F

P

P

P

H

P

H

P

H

P

B

12 SECT

F

P

P

P

P

H

P

H

P

H

P

B

F = Front Section

P = Plain intermediate section

H = Heater intermediate section-Optional, must be ordered. B = Back Section

CAUTION

Due to the fact that the sections are top heavy, it is absolutely necessary that the back section be supported in such a manner as to prevent its falling and causing potential serious bodily injury while preparing to add the next section. One such way would be to insert a piece of 3" x 36" piping in the lower port.

NOTE

Some sections may need shims under support feet to align with other sections.

Stand the back section in place with the feet on and in the angle iron rails. Support the section as required to prevent it from falling forward or rearward. Clean hydronic gasket recesses and rope groove with a stiff wire brush. Apply spray-on adhesive (supplied with the boiler) to rope groove to hold wicking in place during assembly.

CAUTION

Do not spray adhesive into the hydronic seal ports.

Apply a length of wicking avoiding bends and twists. Be sure ends extend past the cleanout cover opening. (See FIGURE 2) Place the upper and lower hydronic seals in the recessed section taking care not to dislodge the rope or the hydronic seals. Inspect the alignment of the sections through the open ports and, if properly aligned, install the draw rods with nuts drawn hand-tight. (See FIGURE 3.) Plumb the sections before applying torque to the upper right and lower left draw rods. Maintain finger-tight torque on upper left and lower right draw rods.

CLEANOUT COVER

HEATING	UPPER PORT
SURFACE

CERAMIC ROPE JOINT SEAL

LOWER PORT

FLOOR

SECTIONAL VIEW

FIGURE 2

IMPORTANT

The upper and lower ports should be drawn up metal to metal around the outside of the hydronic seal. Metal to metal conditions will not occur at any other location. Avoid excessive torque on upper left and lower right draw rods, which may warp the section. See FIGURE 3 for correct alignment of the seal.

Assemble additional sections as described above.

After draw rods are hand tight, torque as shown in TABLE 3.