Smith Cast Iron Boilers GB200 User Manual
GB200-IM-5
42-9184
GB200 SERIES
INSTALLATION, OPERATION
& MAINTENANCE MANUAL
WITH REPLACEMENT
PARTS LIST
GAS-FIRED STEAM
CAST IRON BOILERS
85,000 TO 165,000 BTUH INPUT
INTERMITTENT PILOT/VENT DAMPER
& STANDING PILOT/VENT DAMPER
SECTION 1: INTRODUCTION
Code Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Venting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Chimney Requirements . . . . . . . . . . . . . . . . . . . . . . . . . .3
Combustion Air Requirements . . . . . . . . . . . . . . . . . . . . .3
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Shipment of Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
SECTION 2: BOILER INSTALLATION
Step 1: Locating/Setting Boiler . . . . . . . . . . . . . . . . . . . . .4
Step 2: Installing Steam Piping . . . . . . . . . . . . . . . . . . . .5
Step 3: Installing Hydronic Components . . . . . . . . . . . . .5
Step 4: Venting Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Step 5: Installing/Testing Gas Piping . . . . . . . . . . . . . . . . .7
Step 6: Wiring Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
SECTION 3: START-UP & OPERATION
Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . . .11
Prior To Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Start-Up & Adjustments . . . . . . . . . . . . . . . . . . . . . . . . .11
SECTION 4: MAINTENANCE
Before Each Heating Season . . . . . . . . . . . . . . . . . . . . .14
Steam Boiler Cleaning Instructions . . . . . . . . . . . . . . . . .15
How To Change Orifices . . . . . . . . . . . . . . . . . . . . . . . . .15
Heating System Problems & Causes . . . . . . . . . . . . . . .15
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . .16-17
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
TABLE OF CONTENTS
WESTCAST, INC.
260 NORTH ELM STREET WESTFIELD, MA 01085
TEL. (413) 562-9631 FAX (413) 562-3799
www.smithboiler.com
2
SECTION 1: INTRODUCTION
The following terms are used throughout this manual to bring
attention to the presence of potential hazards or to important
information concerning the product:
CAUTION: Indicates a potentially hazardous situation
which, if not avoided, may result in minor injury or property damage.
NOTE: Used to notify of special instructions on installation, operation or maintenance which are important to
equipment but not related to personal injury hazards.
CODE COMPLIANCE
Boiler installations must conform to the requirements of the
authority having jurisdiction or, in the absence of such
requirements, to the National Fuel Gas Code ANSI Z223.1latest edition. Where required by the authority having jurisdiction, the installation must also conform to the American Society of Mechanical Engineers Code for "Controls and Safety
Devices for Automatically Fired Boilers", ANSI/ASME CSD-1.
All electrical wiring must be in accordance with National
Electric Code ANSI/NFPA No.70-latest edition and any additional state or local code requirements. If an external source
is utilized, the boiler, when installed, must be electrically
grounded in accordance with requirements of the authority
having jurisdiction or, in the absence of such requirements,
with the National Electrical Code, ANSI/NFPA No.70-latest
edition. UL listed power limited circuit cable is almost universally approved for safety controls on heating equipment,
either internally or externally, without protection of conduits or
raceway.
VENTING REQUIREMENTS
When connecting to gas vents or chimneys, vent installations
shall be in accordance with Part 7, Venting of Equipment, of
the National Fuel Gas Code, ANSI Z223.1-latest edition, or
applicable provisions of the local building codes.
Vent connectors serving appliances vented by natural draft
shall not be connected into any portion of mechanical draft
systems operating under positive pressure.
When two or more appliances vent into a common flue, the
area of the common flue should be at least equal to the area
of the largest flue plus 50% of the areas of the additional flue
or vent connectors.
When existing boiler is removed from common venting system, common venting system is likely to be too large for
proper venting of appliances remaining connected to it. At
time of removal of existing boiler, the following steps shall be
followed with each appliance remaining connected to the
common venting system placed in operation, while other
appliances remaining connected to the common venting system are not in operation:
1. Seal all unused openings in common venting system.
2. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other deficiencies
which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on
clothes dryers and any appliance not connected to the
common venting system. Turn on any exhaust fans, such
as range hoods and bathroom exhausts, so they will
operate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.
4. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
5. Test for spillage at draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match
or candle, or smoke from cigarette, cigar or pipe.
6. After it has been determined that each appliance remaining connected to common venting system properly vents
when tested as outlined above, return doors, windows,
exhaust fans, fireplace dampers and any other gas-burning appliance to previous conditions of use.
7. Any improper operation of the common venting system
should be corrected so the installation conforms with
National Fuel Gas Code, ANSI Z223.1-latest edition.
When resizing any portion of the common venting system, the common venting system should be resized to
approach the minimum size as determined using the
appropriate tables in Appendix G in the National Fuel
Gas Code, ANSI Z223.1-latest edition.
WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage.
DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death, serious
injury or substantial property damage.
CHIMNEY REQUIREMENTS
DANGER: A chimney which does not meet modern
safety standards will result in a fire or deadly carbon
monoxide poisoning of the building residents.
Chimney condition is of paramount importance for a safe and
efficient boiler installation. All new and replacement installations must include a chimney inspection by a qualified individual or agency. Chimney construction materials must be
compatible with the fuel being used.
Particular attention should be paid on all oil-to-gas conversions. Soot may have accumulated in chimney and/or
degraded chimney liner. Most utilities require complete chimney cleaning. Others may require installation of new liner,
spill switches or other chimney upgrades. Check with local
utility for required safety precautions.
COMBUSTION AIR REQUIREMENTS
Provisions for combustion air must be in accordance with the
National Fuel Gas Code ANSI Z223.1 - latest edition, as well
as all applicable local codes. If the boiler is installed in an
unconfined space, adequate air will be available via normal
infiltration. However, if building construction is unusually tight
or the boiler is installed in a confined space (a space whose
volume is less than 50 cubic feet per 1000 Btu/hr of gas input
for all fuel burning equipment), adequate air for combustion
must be provided by two openings: one located about 6”
below the ceiling, the other about 6” above the floor. When
communicating directly with the outside or through a vertical
duct, each opening must have a minimum free area of one
square inch per 4000 Btu/hr of gas input. Horizontal ducts to
the outside must have a minimum free area of one square
inch per 2000 Btu/hr of gas input. When ventilation is provided by openings in doors, etc. to adjoining spaces having adequate infiltration, each opening must have a minimum free
area of one square inch per 1000 Btu/hr of gas input.
3
NOTE: Boiler employs atmospheric combustion. Combustion air must not be contaminated with halogenated
hydrocarbon vapors, aerosol propellants or freon. Otherwise, boiler heat exchanger will be subject to corrosion,
reducing boiler life.
WATER TREATMENT
Water treatment is recommended in areas where water quality is a problem. A local water treatment company should be
consulted to determine the requirements for your particular
system and locality.
NOTE: Boiler is not for use in systems where water is
replenished. Minerals in the water can build up on the
heat transfer surfaces and cause overheating and subsequent failure of the heat exchanger.
NOTE: Boiler utilizes synthetic rubber seals. Water treatment chemicals and system cleaning chemicals must be
compatible with this and all other construction materials.
SHIPMENT OF BOILER
Each boiler is shipped in a single carton.
Optional Vent Damper
When ordered, the vent damper is shipped in an individual
carton packaged with the boiler. Mounting of the damper and
flue outlet extension are required.
WARNING: Adequate fresh air must be provided for
combustion. Improper boiler operation and inadequate venting of deadly flue gases may otherwise
result.
4
FIGURE 2.1: MODEL GB200 BOILER DIMENSIONS
WARNING: Never install boiler on carpeting as heat
damage and/or fire may result.
STEP 1: LOCATING/SETTING BOILER
Boiler may be installed in an alcove (see dimensions in Figure 2.1). Locate boiler so connecting flue pipe between draft
hood and chimney is as short as possible.
Observe the following minimum clearances to combustibles:
18" on sides...alcove at front...28" at top...18" at rear...6" from
flue pipe in any direction. Maintain a minimum 1” clearance
between hot water piping and combustible materials. Local
code requirements may specify greater clearances and must
be adhered to.
Remove boiler from carton and set it in position. Install on
non-combustible floor only, unless local codes permit use
and fabrication of a fireproof base (see Figure 2.2).
Remove all packing material from boiler. Check that burners,
draft diverter and controls are in proper position.
Boiler shall be installed such that the gas ignition system
components are protected from water (dripping, spraying,
rain, etc.) during appliance operation and service (low water
cut-off repacement, condensate trap replacement, control
replacement).
NOTE: Do not loosen tie rods on boiler absorption unit.
They are intended to accommodate thermal expansion.
Loss of boiler's structural integrity and water leaks/damage may result.
SECTION 2: BOILER INSTALLATION
PRESS.
GAUGE
LOW
WATER
CUT-OFF
41"
2 1/2"
21"
14 3/4"
2" RETURN
FRONT
MINIMUM CLEARANCES
TO COMBUSTIBLES
Top: 28"
Rear: 18"
Left & Right: 18"
Front: ALCOVE
WATER
LINE
A
23 1/4"
18 1/4"
3/4" PLUGGED
TAPPING
26 7/8"
2" RETURN
REAR
18 1/8"
B
SPILL SWITCH
9 7/8"
16 1/2"
18 1/8"
21 7/8"
20"
BOILER
MODEL
GB200-S-3
GB200-S-4L
GB200-S-4H
GB200-S-5
PRESSURE CONTROL
3"
2" STEAM
SUPPLY
WATER
LEVEL
INDICATOR
1/2"
PLUGGED
TAPPING
23 1/4"
3 3/8"
2 3/8"
15 3/8"
18 7/8"
18 7/8"
22 3/8"
PRESS.
RELIEF VALVE
GAS
VALVE
6 3/4"
DIMENSIONS
A
B
5"
6"
6"
7"
ROLLOUT SWITCH
-LEFT SIDE VIEW- -FRONT VIEW- -RIGHT SIDE VIEWPROBE LOCATION
FOR ELECTRIC
LWCO.
NOTE: OPTIONAL FLOAT LOW WATER CUT-OFF SHOWN.
23 7/8"
14 3/4"
2 1/2"
5
STEP 2: INSTALLING STEAM PIPING
Typical piping connections are shown in Figure 2.3. All external piping must be supported by hangers, not by the boiler or
its accessories.
Supply outlet must run full size from the boiler to a header at
least 24" above top of boiler. Condensate return piping
should be connected to boiler through a "Hartford Loop."
Install gate valves in supply and return.
Proper steam piping practices must be followed at all times.
Maintain proper clearances between piping and combustible
material.
The supply and return lines should be equipped with drain
cocks to drain sediment and sludge from lowest points of
boiler.
STEP 3: INSTALLING HYDRONIC COMPONENTS
A low-water cutoff must be installed to protect the unit from
dry fire.
Screw extension nipple into 3/4" tapping on top of the
absorption unit and install relief valve into top of nipple with
the spindle in the vertical position (i.e., with the valve discharge in the horizontal).
Most localities require the discharge piping to terminate within 6" of the floor. Check local code requirements if in doubt.
Discharge piping must be of same size or larger than the
relief valve outlet and should be run as short and straight as
possible. Elbows in the discharge piping should be placed as
close to the valve as possible. If valve discharge is to be
drained away, the discharge piping must not be hard-piped to
the drain piping (i.e., an open funnel or similar arrangement
must be used).
CAUTION: Piping must be installed from the relief valve
discharge so there will be no danger of scalding personnel.
FIGURE 2.2: RECOMMENDED FIREPROOF BASE
FIGURE 2.3: TYPICAL STEAM BOILER PIPING
WARNING: Never install any type of valve between
the boiler and the relief valve or an explosion causing
extensive property damage, severe personal injury or
death may occur!
6" OVERHANG OF BLOCKS
AND SHEETMETAL ALL
AROUND
6"
22 GAUGE
SHEETMETAL
4" HOLLOW CLAY
TILE (TWO COURSES)
OPENINGS THRU BLOCKS
IN TOP COURSE TO
BE AT 90° ANGLE
TO OPENINGS THRU
BOTTOM COURSE
FLOOR
STEAM
SUPPLY
GATE VALVE
MUST BE CLOSE
NIPPLE
HARTFORD
LOOP
GATE
VALVE
RETURN
DRAIN
COCKS
RETURN
TAPPING
2" NPT
COLD WATER FILL
SUPPLY
TAPPING
3" NPT
12" MIN.
WATER LINE
C/L OF HARTFORD
LOOP TO BE 2"
BELOW WATER
23 1/4"
LINE
6
STEP 4: VENTING BOILER
A factory-mounted spill switch is provided on all GB200 boilers (see Figures 2.4 & 2.4A).
The flue or vent connectors must be installed flush with the
inside chimney liner surface and sealed in place with furnace
cement. Horizontal positions of the single wall and type B
venting systems shall be supported by use of strap hangers
or their equivalent. Vent supports should be placed a maximum of 15 feet apart and as required to prevent sagging.
The vent connectors shall be pitched 1/4" per foot upwards
towards the chimney or vent termination.
Installing Vent Damper
The vent damper must be mounted directly on top of the draft
diverter. The vent outlet extension must be installed between
the damper and the outlet to allow the damper plate to open
and close.
Locate the motor on the front side and position the cable so
that it does not touch the metal surface of the draft diverter
(see Figure 2.4). If necessary, turn angle connector on vent
damper upward until cable clears; tighten locknut to secure.
The direction of the flow arrow imprinted on the vent damper
must point upward. The damper position indicator, which is
located on the side of the vent damper opposite the motor,
must be visible.
CAUTION: A minimum of 6" between vent damper and
combustible materials must be maintained. The vent
damper must be accessible for servicing and checking
position indicator.
If applicable, remove hair pin shipping clip which holds
damper blade in closed position and observe that damper
blade rotates slowly to open position. Do not force it closed
as it may damage the gear train and void the warranty. The
blade should move freely and without obstruction.
Secure the vent damper housing to the draft diverter outlet
with sheet metal screws or pop rivets. Refer to Figure 2.5 for
fastener locations. Install flue pipe over top of vent damper
and secure to damper housing with sheet metal screws or
pop rivets.
Attach vent damper cable to cable clamp on boiler left panel
and join the Molex connector (see Figures 2.4 & 2.4A).
DANGER: Draft diverter, vent outlet and vent damper
as supplied must not be altered in any way, as proper
boiler operation would be jeopardized. Flame rollout,
fire or carbon monoxide poisoning will result.
DANGER: Only the boiler may be served by the vent
damper. Do not attempt to use it to vent an additional appliance. This will cause fire or carbon monoxide
poisoning.
FIGURE 2.4A: VENT DAMPER INSTALLATION
FOR STANDING PILOT
FIGURE 2.4: VENT DAMPER INSTALLATION
FOR INTERMITTENT PILOT
VENT DAMPER
PRESSURE
SPILL
SWITCH
CABLE
BRACKET
DK. BLUE
CONTROL
THERMOSTAT
CONNECTION
TRANSFORMER
THERMOSTAT
CONNECTION
PILOT
CONTROL
VENT DAMPER
PRESSURE
SPILL
SWITCH
CABLE
BRACKET
DK. BLUE
CONTROL
THERMOSTAT
CONNECTION
TRANSFORMER
GAS
VALVE
THERMOSTAT
CONNECTION
Loading...