Smith Cast Iron Boilers GB250 User Manual

GB250-IM-5 42-9185

GB250 SERIES

INSTALLATION, OPERATION & MAINTENANCE MANUAL

AND REPLACEMENT PARTS LIST

Gas-Fired Steam Cast Iron Boilers

175,000 to 400,000 Btuh Input

Standing Pilot, Standing Pilot & Vent Damper,

Intermittent Pilot, Intermittent Pilot & Vent

Damper

	SECTION 1: INTRODUCTION			..............................................Step 6: Wiring Boiler									11
	Code Compliance. ....................................................	2
	Venting Requirements ..............................................	3		SECTION 3: START-UP & OPERATION
	Chimney Requirements ............................................	3		Sequence Of Operation ..........................................									16
	Combustion Air Requirements ..................................	3		Prior To Start-Up ....................................................									16
	Water Treatment........................................................	4		Start-Up & Adjustments ..........................................									16
	Shipment of Boiler ....................................................	4
				SECTION 4: MAINTENANCE
	SECTION 2: BOILER INSTALLATION			Before Each Heating Season..................................									19
	Step 1: Locating/Setting Boiler..................................	5		How To Change Orifices ........................................									20
	Step 2: Installing Steam Piping ................................	6		Heating System Problems & Causes ......................									20
	Step 3: Installing Hydronic Components ..................	7		Replacement Parts List ..........................................									21
	Step 4: Venting Boiler................................................	7		Warnings ................................................................									25
	Step 5: Installing/Testing Gas Piping ......................	10

WESTCAST, INC.

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

SECTION 1: INTRODUCTION

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 Z223.1-latest edition. Where required by the authority having jurisdiction, the installation must also conform to the Standard 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, 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.

For Canada, the installation must be in accordance with Standards CGA B149.1 and B149.2 Installation Codes for Gas Burning Appliances and Equipment and/or local codes. All electrical connections are to be made in accordance with Standard C.S.A. C22.1 Canadian Electrical Code, Part 1 and/or local codes.

BOILER			DIMENSIONS					FOR MODELS SUPPLIED WITH VENT
								DAMPER ADD 3 5/8" TO DIM. E
MODEL	A	B		C		D	E
GB250-S-5L	22 1/2"	18"		10 1/2"		7"	25"
GB250-S-5H	22 1/2"	18"		10 1/2"		7"	25"
GB250-S-6	26"	21 1/2"		12 1/2"		8"	30"
GB250-S-7	29 1/2"	25"		14"		8"	30"
GB250-S-8	29 1/2"	28 1/2"		15 1/2"		9"	37"
GB250-S-9	36 1/2"	32"		17 1/2"		9"	37"

	SPILL SWITCH		D
	PRESSURE CONTROL
*E		PRESSURE
	3"	RELIEF VALVE	B
9 3/8"	3" STEAM
	SUPPLY

	PRESS.	8 15/16"		C
	GAUGE		1/2" PLUGGED
				3/4" PLUGGED
			TAPPING
				TAPPING

	LOW		WATER
	WATER
31 1/2"
	CUT-OFF		LINE
		3 3/4"
				2 1/2"
			26 7/8"
	2 1/2"	23 1/4"	ROLLOUT SWITCH	23 7/8"
		28 1/2"
21"			23 1/4"
	20"	TRANSF.	2" RETURN
	14 3/4"
		115/24V	REAR	14 3/4"
			18 1/4"
		GAS VALVE

16 1/2"

6 3/4"

A

2" RETURN

18 1/8"

21 7/8"

FRONT

-LEFT SIDE VIEW-

-FRONT VIEW-

-RIGHT SIDE VIEW-

PROBE LOCATION FOR ELECTRIC LWCO.

The following terms are used throughout this manual to bring attention to the presence of potential hazards or to important information concerning the product:

DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial property damage.

WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage.

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.

2

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. For Canada, the provisions of B149.1 and B149.2 shall apply.

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 an 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. For Canada, the provisions of B149.1 and B149.2 shall apply.

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 REQUIREMENTS

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

WARNING: Adequate fresh air must be provided for combustion. Improper boiler operation and inadequate venting of deadly flue gases may otherwise result.

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. Draft hood is shipped in a separate carton on larger models.

Optional Vent Damper

When ordered, the vent damper is shipped in an individual carton packaged with the boiler. Mounting of the damper is required.

WARNING: Installers must follow local regulations with respect to the installation of CO detectors and follow the manufacturer’s stated maintenance schedule for this boiler!

ATTENTION: Observer les règlements règional à l’egard des détecteurs de monoxyde de carbone et observer entretien de manufacturier pour cette chaudière!

4

SECTION 2: BOILER INSTALLATION

STEP 1: LOCATING AND SETTING THE BOILER

PROCEDURE A: Check that provisions for combustion air are in accordance with National Fuel Gas

Code ANSI Z223.1-latest edition and all applicable local codes. In Canada, follow CAN/CGA B149(.1 or .2) installation codes.

PROCEDURE B:			FIGURE 2.1
Check minimum	6"	6"
clearances to
combustibles are
proper as shown. Local		VENT DAMPER
requirements may
		* TOP
specify greater
clearances & must be
adhered to.
Boiler shall be install-	18"	12"	12"
ed such that the gas		RECOMMEND
ignition system com-		MORE FOR
		ACCESS TO
ponents are protected		VENT DAMPER
		POSITION
from water (dripping,		INDICATOR
spraying, rain, etc.)
during appliance oper-
ation and service.
		* 52" FOR GB250-S-5L THRU GB250 S-7
		58" FOR GB250-S-8 THRU GB250-S-9

WARNING: Never install boiler on combustible flooring without combustible flooring pan or on carpeting as heat damage and/or fire may result.

CAUTION: Locate boiler so horizontal connecting flue pipe is as short as possible. Maximize height of vertical flue connector.

NOTE: Do not loosen tie rods on absorption unit. They accommodate thermal expansion. Loss of boiler structural integrity and water leaks/damage may result.

Step 1 Continued On Next Page

5

PROCEDURE C:

Check component positioning.

1.Remove all packing material from boiler.

2.Install on non-combustible floor only, unless local codes permit use and fabrication of a fireproof base (see Fig. 2.2).

3.Check that burners and controls are in the proper position.

4" HOLLOW CLAY TILE (TWO COURSES) OPENINGS THRU BLOCKS IN TOP COURSE TO

BE AT 90 0 ANGLE TO OPENINGS THRU BOTTOM COURSE

6" OVERHANG OF BLOCK AND SHEETMETAL ALL AROUND

22 GAUGE

6" SHEETMETAL

FIGURE 2.2

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 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.

	STEAM
	SUPPLY
	GATE VALVE
		SUPPLY
MUST BE CLOSE		TAPPING
NIPPLE		3" NPT
HARTFORD
LOOP
GATE	RETURN
	TAPPING
VALVE
	2" NPT
RETURN
	COLD	WATER
		FILL

DRAIN

COCKS

24" MIN.

WATER LINE

C/L OF HARTFORD

LOOP TO BE 2"

BELOW WATER

LINE

23-1/4"

FIGURE 2.3

6

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)(See Figure 2.4).

WARNING: No Valve of any type may be installed between the boiler and the relief valve to prevent accidental explosion from overpressure.

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.

PRESSURE

RELIEF VALVE

PRESSURE RELIEF

VALVE DISCHARGE

PIPING

FIGURE 2.4

STEP 4: VENTING BOILER

DANGER: Drafthood, vent outlet and vent damper as supplied must not be altered in any was as proper boiler operation would be jeopardized. Flame rollout, fire or carbon monoxide poisoning will result.

Install draft hood on boiler. If the draft hood shroud has a hole near the relief opening for installing a spill switch, mount draft hood so the hole faces to the front of the boiler. Spill switches are provided on Model GB250-5L,

GB250-5H, and GB250-6 boilers.

Applicable boiler is equipped with a factory-mounted spill switch harness/mounting bracket assembly; spill switch is provided in plastic bag. See Figure 2.5. Install mounting bracket on outside surface of draft hood shroud with screws provided (HARNESS MUST BE ON OUTSIDE OF SHROUD). Install spill switch in hole in shroud (on outside surface) with screws provided. Plug wiring leads from harness/bracket assembly onto flat terminals on spill switch.

NOTE: Boiler will not operate unless wiring leads to spill switch are connected.

INSTALL

CONNECT

INSTALL

SWITCH

WIRE

MOUNTING

IN OPENING

LEADS

BRACKET

ON DRAFTHOOD

ON DRAFTHOOD

FIGURE 2.5

If vent damper is supplied with boiler, it must be installed between the top of the draft hood and the flue pipe. See “Installing The Vent Damper” instructions.

Connect draft hood to chimney or Class B vent. Flue pipe must be same diameter as the draft hood outlet.

7

The flue or vent connectors must be installed flush with the inside chimney liner surface and sealed in place with furnace cement. Horizontal portions 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.

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.

Installing Vent Damper

The vent damper must be mounted directly on top of the draft hood.

Locate the motor on the front side and position the cable so that it does not touch the metal surface of the drafthood (see Figure 2.6). 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.

Remove hairpin 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 drafthood outlet with sheet metal screws or pop rivets. Refer to Figure 2.8 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 Figure 2.6 or Figure 2.6A).

FLOW DIRECTION

ARROW POINTS UP

MAKE SURE

MOTOR IS

LOCATED ON

FRONT SIDE

MOUNT VENT

DAMPER OVER

DRAFTHOOD

FIGURE 2.7

	VENT DAMPER	PRESSURE	VENT DAMPER	PRESSURE
		CONTROL		CONTROL
	DRAFTHOOD	THERMOSTAT	DRAFTHOOD	THERMOSTAT
		CONNECTION		CONNECTION

CABLE	CABLE
BRACKET	BRACKET
TRANSFORMER	TRANSFORMER

PILOT CONTROL	GAS VALVE
BLUE	BLUE
.DK	.DK
THERMOSTAT CONNECTION	THERMOSTAT CONNECTION

FIGURE 2.6: Vent Damper Installation for Intermittent Pilot

FIGURE 2.6A: Vent Damper Installation for Standing Pilot

8

ATTACH LOWER

PORTION OF

VENT DAMPER

TO DRAFTHOOD

OUTLET WITH 1/2"

OR SHORTER

SCREWS OR

POP RIVETS

FIGURE 2.8

PROCEDURE C: Install flue pipe between vent damper and chimney (6" minimum clearance required between flue pipe and combustibles).

USE VENT SUPPORT(S) AS REQUIRED TO PREVENT SAGGING

SINGLE WALL OR TYPE B FLUE PIPE

MAXIMUM

6 FT.

APART

PITCH 1/4" PER FOOT

SECURE

FLUE PIPE

INSTALL

TO VENT

FLUSH

DAMPER

WITH

CHIMNEY

LINER

SEAL

WITH

FURNACE

FIGURE 2.9

ADDITIONAL 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 an existing boiler is removed from a 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, following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while other appliances remaining connected to 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 installation conforms with the 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. For Canada, the provisions of CAN/CGA B149(.1 or .2) shall apply.

ADDITIONAL CHIMNEY REQUIREMENTS: Chimney condition is of paramount importance for a safe and efficient boiler installation. All installations must include a chimney inspection by a qualified individual or agency. Chimney construction materials must be compatible with the fuel being used.

Par ticular 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.

DANGER: A chimney which does not meet modern safety standards will result in a fire or deadly carbon monoxide poisoning of the building residents.

9