GB300-IOM-4
GB300
NATURAL OR PROPANE GAS BOILER
INSTALLATION & OPERATING MANUAL
Designed and tested according to A.S.M.E. Boiler and Pressure Vessel Code, Section IV for a maximum allowable working pressure of 80 psi US, 50 psi Canada water, 15 psi steam.
CAUTION: Do not use automotive anti-freeze in the boiler waterways. If the use of antifreeze is necessary an anti-freeze specifically formulated for hydronic heating systems must be used!
Water treatment is not recommended. This boiler uses gaskets made from ethylene propylene, EPT, to seal the section ports. Consult a water treatment professional before adding any chemicals to the boiler water to ensure that they are compatible with the gaskets. Failure to comply with this caution can result in failure of the gaskets voiding the warranty.
WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
•Do not try to light any appliance.
•Do not touch any electrical switch. Do not use any phone in your building.
•Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.
•If you cannot reach your gas supplier, call the fire department.
A qualified installer, service agency or the gas supplier, must perform installation and service.
INSTALLER READ THESE INSTRUCTIONS CAREFULLY.
THEY WILL SAVE YOU VALUABLE TIME WHEN ASSEMBLING THE BOILER.
THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER. CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.
WESTCAST, INC.
260 NORTH ELM STREET WESTFIELD, MA 01085
TEL. (413) 562-9631 FAX (413) 562-3799 www.smithboiler.com
Page 2
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Assurez-vous de bien suivre les instructions données dans cette notice pour réduire au minimum le risque d'incendie ou d'explosion ou pour éviter tout dommoge matériel, toute blessure ou la mort
Ne pas entreposer ni utiliser d'essence ou ni d'autres vapeurs ou liquides inflammables à proximité de cet appareil ou de tout autre appareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
•Ne pas tenter d'allumer d'appareil.
•Ne touchez à aucun interrupteur; ne pas vous servir des téléphones se trouvant dans le bâtiment.
•Appelez immédiatement votre fournisseur de gas depuis un voisin. Suivez les intructions du fournisseur.
•Si vous ne purvez rejoindre le fournisseur, appelez le service des incendies.
L'installation et l'entretien doivent être assurés par un installateur ou un service d'entretien qualifié ou par le fournisseur de gaz.
CONTENTS
Getting Started ................................................... |
page 2 |
Boiler Ratings & Capacities ................................ |
page 3 |
Boiler Location ................................................... |
page 3 |
Combustion Air & Ventilation .............................. |
page 4 |
Chimney & Vent Pipe Connections .................... |
page 5 |
Boiler Assembly .............................................. |
page 11 |
Heating System Piping ..................................... |
page 35 |
Gas Supply Piping ............................................ |
page 39 |
Electrical Wiring ............................................... |
page 40 |
Boiler Operation .............................................. |
page 41 |
Lighting Instructions ......................................... |
page 42 |
Boiler Checking & Adjustment .......................... |
page 43 |
Boiler Maintenance .......................................... |
page 44 |
Repair Parts ..................................................... |
page 46 |
Health Warnings .......................................... |
back cover |
All aspects of the boiler installation 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/NFPA - latest revision. Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.
This product must be installed by a licensed plumber or gas fitter when installed within the Commonwealth of Massachusetts.
In Canada, the installation must be in accordance with the requirements of CAN/CGA B149.1 or .2, Installation Code for Gas Burning Appliances and Equipment.
BEFORE YOU START
This manual covers the application, installation, operation and maintenance of a GB300(S,W) low pressure steam or hot water boiler.
To obtain the safe, dependable, efficient operation and long life for which this boiler was designed, these instructions must be read, understood and followed.
The GB300(S,W) boilers have been design certified by CSA for use with natural and propane gas under the latest revision of ANSI-Z21.13/CSA 4.9 Gas-Fired Low Pressure Steam and Hot Water Boilers and CGA 3.3, Gas-Fired Steam and Hot Water Boilers. Each unit has been constructed and hydrostatically tested for a maximum working pressure of 80 psi US, 50 psi Canada, 15 psi steam in accordance with Section IV of the A.S.M.E. Boiler and Pressure Vessel Code for cast iron boilers.
The owner should maintain a record of all service work performed with the date and a description of the work done. Include the name of the service organization for future reference.
Direct all questions to your Smith Cast Iron Boiler distributor or contact the Smith Customer Service Department, 260 North Elm Street, Westfield, MA 01085. Always include the model and serial numbers from the rating plate of the boiler in question.
Page 3
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
BOILER RATINGS & CAPACITIES
Before undertaking the installation of the GB300(S,W) boiler check the boiler rating plate to ensure that the boiler has been sized properly for the job. The rating label has been packed with the controls. The “Net I=B=R Ratings” specify the equivalent amount of direct cast iron radiation that the boiler can supply under normal conditions. Also ensure that the boiler has been set up for the type of gas available at the installation site. Other important considerations are the availability of an adequate electrical supply, fresh air for combustion and a suitable chimney or vent system.
BOILER LOCATION
1.Locate the boiler in an area that provides good access to the unit. Servicing may require the removal of jacket panels. Allow a minimum clearance of 2 ft, 0.61 m between adjacent construction and the boiler sides and draft hood. A minimum clearance of 4 ft, 1.22 m must be maintained between the front of the boiler and adjacent construction. Accessibility clearances should take precedence over fire protection clearances, or use which ever is greater.
2.An optimum site will be level, central to the piping system, close to a chimney and have adequate fresh air for combustion.
3.Ensure that the floor is structurally sound and will support the weight of the boiler. Never install a GB300(S,W) on a concrete floor that contains wires, cables, water pipes or hoses. This boiler is designed for non combustible floors only! Never install this boiler on combustible materials or carpeting even if a noncombustible foundation material is placed over them!
WARNING: Never install a GB300(S,W) boiler on top of combustible flooring! Failure to comply with this warning may result in a fire causing extensive property damage, severe personal injury or death!
4. DO NOT install this boiler in a location that would subject any of the gas ignition components to direct contact with water or excessive moisture during operation or servicing. A full concrete foundation is recommended to protect the boiler from moisture and debris, Figure 1.
NOTE: The boiler must be assembled on a level, noncombustible surface. If the floor is not level a pad must be poured to provide a level surface. If a concrete block base is used level it using noncombustible shims or grout.
5. DO NOT place this boiler in a location that would restrict the introduction of combustion air into the boiler.
WARNING: Never store combustible materials, gasoline or any product containing flammable vapors or liquids in the vicinity of the boiler. Failure to comply with this warning can result in an explosion or fire causing extensive property damage, severe personal injury or death!
Figure 1 |
Concrete Block Base Construction |
Page 4
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
COMBUSTION AIR & VENTILATION
WARNING: This boiler must be supplied with combustion air in accordance with Section 5.3, Air for Combustion & Ventilation, of the latest revision of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and all applicable local building codes. Canadian installations must comply with CAN/CGA B149.1 or .2 Installation Code. Failure to provide adequate combustion air for this boiler can result in excessive levels of carbon monoxide which can result in severe personal injury or death!
WARNING: Never operate a GB300 in an environment subjected to a negative pressure unless it is Direct Vented. Failure to comply with this warning can result in excessive levels of carbon monoxide causing severe personal injury or death!
To operate properly and safely this boiler requires a continuous supply of air for combustion. Oxygen is used by the boiler burners to burn the gas. NEVER store objects on or around the boiler. In addition, air is also used to assist in the safe disposal of the products of combustion. This air is known as dilution air and mixes with the products of combustion to assist in their exit through the flue pipe and chimney. An adequate supply of air must be available to replace the air used by these processes.
Older buildings often have enough natural infiltration to provide an adequate amount of combustion air provided that the demand for combustion air is not too great.
Buildings that are relatively new or “tight” will most likely require the installation of a fresh air duct or other means of providing make-up air. Any building utilizing other gas burning appliances, a fireplace, wood stove or any type of exhaust fan must be checked for adequate combustion air when all of these devices are in operation at one time. Sizing of an outside air duct must be done to meet the requirements of all such devices.
All Air From Inside The Building
If the boiler is to be located in a confined space minimum clearances of 2 ft, 0.61 m must be maintained between the boiler and any adjacent construction. When installed in a confined space two permanent openings communicating with an additional room(s) are required. The combined volume of these spaces must have sufficient volume to meet the criteria for an unconfined space. The total air requirements of all gas utilization equipment, fireplaces, wood stoves or any type of exhaust fan must be considered when making this determination.
Each opening must have a minimum free area of 1 in2/1000 Btu/hr, 2200 mm2/kW based on the total input rating of ALL gas utilization equipment in the confined area. Each opening must be no less than 100 in2, 64,516 mm2 in size. The upper opening must be within 12 in, 300 mm of, but not less than 3 in, 80 mm from, the top of the enclosure. The bottom opening must be within 12 in, 300 mm of, but not less than 3 in, 80 mm from, the bottom of the enclosure.
All Air From Outside The Building
When installed in a confined space two permanent openings communicating directly with, or by ducts to, the outdoors or spaces that freely communicate with the outdoors must be present. The upper opening must be within 12 in, 300 mm of, but not less than 3 in, 80 mm from, the top of the enclosure. The bottom opening must be within 12 in, 300 mm of, but not less than 3 in, 80 mm from, the bottom of the enclosure.
Where directly communicating with the outdoors or communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of 1 in2/4000 Btu/hr, 550 mm2/kW of the total input rating of all of the equipment in the enclosure.
Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 in2/2000 Btu/hr, 1100 mm2/kW of the total input rating of all of the equipment in the enclosure.
When ducts are used, they must have the same crosssectional area as the free area of the opening to which they connect.
When calculating the free area necessary to meet the make-up air requirements of the enclosure, consideration must be given to the blockage effects of louvers, grills and screens. Screens must have a minimum mesh size of 1/4 in, 6.4 mm. If the free area through a louver or grill is not known ducts should be sized per Table 1 below.
Table 1 Make-up Air Duct Sizing
|
Required Cross Sectional Duct Area |
|
||||
Input |
1/4 in, 6.4 mm |
Metal |
Wooden |
|||
(MBH) |
Wire Screen |
Louvers |
Louvers |
|||
|
in2 |
cm2 |
in2 |
cm2 |
in2 |
cm2 |
400 |
100 |
645 |
133 |
858 |
400 |
2581 |
600 |
150 |
968 |
200 |
1290 |
600 |
3871 |
800 |
200 |
1290 |
267 |
1723 |
800 |
5161 |
1000 |
250 |
1613 |
333 |
2148 |
1000 |
6452 |
1200 |
300 |
1935 |
400 |
2581 |
1200 |
7742 |
1400 |
350 |
2258 |
467 |
3013 |
1400 |
9032 |
1600 |
400 |
2581 |
533 |
3439 |
1600 |
10,323 |
1800 |
450 |
2903 |
600 |
3871 |
1800 |
11,613 |
2000 |
500 |
3226 |
667 |
4303 |
2000 |
12,904 |
Page 5
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
CHIMNEY & VENT PIPE CONNECTIONS
WARNING: The vent installation must be in accordance with Part 7,Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.1/NFPA54latest revision or applicable provisions of the local building codes. Canadian installa-tions must comply with CAN /CGA B149.1 or .2 Installation Code. Improper venting of this boiler can result in excessive levels of carbon monoxide, which can result in severe personal injury or death!
Chimney Inspection & Sizing
If this boiler will be connected to a masonry chimney, a thorough inspection of the chimney must be performed. Ensure that the chimney is clean, properly constructed and properly sized. Table 2 lists the equivalent breeching and flue sizes required for the GB300 boilers.
Table 2 Vent Outlet, Equivalent Breeching
& Chimney Size
|
Vent Outlets |
Equivalent Breeching |
||
|
& Chimney size |
|||
|
|
|||
Boiler |
# of outlets/dia. in inches |
Diameter |
||
Model |
inches |
mm |
||
|
||||
GB300-5 |
1@10 |
10 |
254 |
|
GB300-6 |
1@12 |
12 |
305 |
|
GB300-7 |
1@12 |
12 |
305 |
|
GB300-8 |
2@10 |
14 |
356 |
|
GB300-9 |
2@10 |
14 |
356 |
|
GB300-10 |
2@10 |
14 |
356 |
|
GB300-11 |
2@12 |
15 |
381 |
|
GB300-12 |
2@12 |
15 |
381 |
|
GB300-13 |
2@12 |
15 |
381 |
|
GB300-14 |
1@12, 2@10 |
16 |
406 |
|
GB300-15 |
4@10 |
17 |
432 |
|
GB300-16 |
4@10 |
17 |
432 |
|
GB300-17 |
4@10 |
17 |
432 |
|
GB300-18 |
4@10 |
17 |
432 |
|
GB300-19 |
4@10 |
17 |
432 |
|
NOTE: These sizes are based on a 20 foot chimney height.
When more than one appliance is connected to the same chimney flue the flue must be large enough to safely vent the combined output of all the appliances.
WARNING: If an appliance using any type of a mechanical draft system operating under positive pressure is connected to a chimney flue, never connect any other appliances to this flue. Doing so can result in the accumulation of carbon monoxide which can cause severe personal injury or death!
VENT CONNECTIONS
Always use a type B or single wall galvanized metal vent pipe the same diameter as the draft hood flue collar. Use the shortest, straightest vent system possible for the installation. If horizontal runs exceed 6 feet they must be supported at maximum 6 foot intervals with overhead hangers. The vent system should be sloped up towards the chimney at a minimum rate of 1/4 inch/foot and terminate flush with the inside of the chimney flue. Fasten each connection with at least 3 corrosion resistant sheet metal screws.
WARNING: Never modify or alter any part of the boiler’s draft hood. This includes the removal or alteration of any baffles. Never install a vent pipe of a diameter different than that of the boiler draft hood flue collar. Failure to comply with this warning can result in severe personal injury or death.
Always provide a minimum clearance of 6 inches between type C vent pipe and any combustible materials. Type B1 vent may be used, clearance between it and any combustible material must be as listed.
WARNING: Failure to maintain minimum clearances between vent connectors and any combustible material can result in a fire causing extensive property damage, severe personal injury or death!
Page 6
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
COMMON VENT SYSTEMS
If an existing boiler is removed from a common venting system, the common venting system may then be too large for the proper venting of the remaining appliances connected to it. At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.
Au moment du retrait d'une chaudière existante, les mesures suivantes doivent être prises pour chaque appareil toujours raccordé au système d'évacuation commun et qui fonctionne alors que d'autres appareils toujours raccordés au système d'évacuation ne fonctionnent pas: système d'évacuation.
a.Seal any unused openings in the common venting system.
Sceller toutes les ouvertures non utilisées du système d'évacuation.
b.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.
Inspecter de façon visuelle le système d'évacu-ation pour déterminer la grosser et l'inclinaison horizontale qui conviennent et s'assurer que le système est exempt d'obstruction, d'étranglement de fruite, de corrosion et autres défaillances qui pourraient présenter des risques.
c.Where it 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 exhaust, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.
Dans la mesure du possible, fermer toutes les portes et les fenêtres du bâtiment et toutes les portes entre l'espace où les appareils toujours raccordés du système d'évacuation sont installés et les autres espaces du bâtiment. Mettre en marche les sécheuses, tous les appareils non raccordés au système d'évacuation commun et tous les ventilateurs d'extraction comme les hottes de cuisinère et les ventilateurs des salles de bain. S'assurer que ces ventilateurs fonctionnent à la vitesse maximale. Ne pas faire fonctionner les ventilateurs d'été. Fermer les registres des cheminées.
d.Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.
Mettre l'appareil inspecté en marche. Suivre les instructions d'allumage. Régler le thermostat de façon que l'appareil fonctionne de façon continue.
Page 7
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
e.Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.
Faire fonctionner le brûleur principal pendant 5 min ensuite, déterminer si le coupe-tirage déborde à l'ouverture de décharge. Utiliser la flamme d'une allunette ou d'une chandelle ou la fumée d'une cigarette, d'un cigare ou d'une pipe.
f.After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous condition of use.
Une fois qu'il a été d éterminé, selon la métode indiquée ci-dessus, que chaque appareil raccordé au système d'évacuation est mis à l'air libre de façor adéquate. Remettre les portes et les fenêtres, les ventilateurs, les registres de cheminées et les appareils au gaz à leur position originale.
g.Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54. 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 Part 11 in the National Fuel Gas Code, ANSI Z223.1/ NFPA 54.
Tout mauvais fonctionnement du systéme d'évacution commun devrait étré corrigé de façor que l'installation soit conforme au National Fuel Gas Code, ANSI
Z223.1/NFPA 54 et (ou) aux codes d'installation CSA-B149. Si la grosseur d'une section du système d' évacuation doit étré modifiée, le système devrait étré modifié pour respecter les valeurs minimales des tableaux pertinents de l'appendice F du National Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) des codes d'installation CSA-B149.
Figure 2A |
Vertical Venting Using A Metal Chimney System And Inside Air(GB300 Series) |
2 FT 0.6 m
10 FT 3.4 m
3 FT 0.9 m
3 FT 0.9 m
Page 8
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Figure 2B |
Dual Flue Outlets And Inside Air (GB300 Series) |
2 FT 0.6 m
10 FT 3.4 m
3 FT 0.9 m
5 FT 4.5 m
Figure 2C |
Vertical Venting Using A Masonry Chimney And Inside Air (GB300 Series) |
10 FT 3.1 m
3 FT 0.9 m
3 FT 0.9 m
Page 9
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Figure 2D |
Dual Flue Outlets Using A Masonry Chimney And Inside Air (GB300 Series) |
10 FT 3.1 m
3 FT 0.9 m
3 FT 0.9 m
Figure 2E |
Common Vents And Inside Air (GB300 Series) |
10 FT 3.1 m
3 FT 0.9 m
3 FT 0.9 m
Page 10
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Figure 2F Dual Flue Outlets With Two Boilers Using A Masonry Chimney And Inside Air (GB300 Series)
10 FT 3.1 m
3 FT 0.9 m
3 FT 0.9 m
Figure 2G |
Horizontal Venting And Inside Air (GB300) |
BUILDING OVERHANG
4 FT 1.2 M MAX.
PITCH PIPE DOWN TOWARDS TERMINAL
CAP 1/4 IN. PER FOOT 20MM/M OF RUN TO
ALLOW FOR CONDENSATE DRAINAGE
3 FT 0.9 m
3 FT 0.9 m
1.5 FT 0.5m MINIMUM
DISTANCE FROM
EXHAUST TO MAXIMUM
SNOW LINE.
Page 11
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
BOILER ASSEMBLY
Locate the boiler installation site based on the guidelines set forth in the previous pages. A full concrete block foundation is recommended to protect the boiler from moisture and debris. Use solid blocks to support the boiler and hollow blocks for the rest, Figure 1. Align the hollow blocks so air can flow through them.
WARNING: Never install a GB300(S,W) boiler on top of combustible flooring! Failure to comply with this warning may result in a fire causing property damage, severe personal injury or death!
Burner Base Assembly General Instructions
WARNING: The burner base must be assembled as outlined below. Do not make substitutions for the hardware or materials supplied for the burner base assemblies. Failure to comply with this warning may result in property damage, severe personal injury or death!
Check the contents of the burner base cartons against the enclosed packing list to ensure that all of the required parts are present. If they are not, contact your Smith Cast Iron Boiler distributor or contact the Smith Customer Service Department.
The burner base panels are factory insulated to simplify field assembly of the burner base.
Box 63273, Burner Base Side Panels & Brackets, contains the left & right burner base side panels, manifold brackets and the jacket brackets, Figure 3.
A box with a number from 63265 to 63272, Burner Base Panels Less Sides, contains the burner base front and rear panels and the burner base baffle, Figure 4.
Figure 4 |
Burner Base Box 63265 to 63272 |
The 5/16 stainless steel nuts and bolts used to assemble the burner base panels are supplied in the X1 box, that has a number from 72700 to 72707 on it, Figure 5.
Use care not to damage or dislodge the ceramic insulation board on the base panels during assembly.
WARNING: If any of the burner base insulation panels are broken or damaged they must be replaced with factory supplied panels. Failure to comply with this warning may result in property damage, severe personal injury or death!
Figure 5 |
X1 Box 72700 to 72707 |
Figure 3 |
Burner Base Box 63273 |
Page 12
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Burner Base Assembly 5 through 12 Sections |
Figure 8 Burner Base Rear Panel Detail, 5 - 12 Sect |
|
Loosely attach the base baffle to the side panels using 4 |
|
|
5/16 stainless steel nuts. Install the burner base front, |
|
|
side and rear panels as shown in Figures 6, 7, 8 and |
|
|
9A. |
|
|
Use a spirit level to ensure that the burner base panels |
|
|
are plumb before tightening the stainless steel nuts and |
|
|
bolts. |
|
|
The factory installed refractory retention bracket(s) must |
|
|
be centered on each piece of refractory board Figure |
|
|
9B. If the bracket is not centered reposition bracket. |
|
|
There is (1) bracket for each section of refractory. |
|
|
Figure 6 |
Burner Base Side Panels, 5 - 12 |
|
Figure 9A Burner Base Rear Panel, 5 - 12 Sect
Figure 7 |
Burner Base Front Panel, 5 - 12 Sect |
Figure 9B |
Refractory Retension Bracket |
Page 13
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Burner Base Assembly 13 through 21 Sections
Box 72694, X7 Splice Channels, contains the burner base front, intermediate and rear channels and additional 5/16" nuts and bolts, Figure 10.
Figure 10 |
X7 Box 72694 |
With the burner base intermediate channel and baffles level, attach the front and rear channels to the intermediate channel. Bolt the burner base side panels to the base baffles, Figure 12.
Figure 12 Burner Base Baffle Front and Rear
Splice Channel Assembly
13 to 21 Sections
The base baffles must be attached to the intermediate base channel before the side, front and rear panels are assembled, Figure 11.
Figure 11 Burner Base Baffle and Intermediate
Splice Channel Assembly
13 to 21 Sections
|
• |
Base Baffle |
Intermediate |
|
Splice Channel |
• |
|
Page 14
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Bolt the front and rear base panels in place, Figure 13. |
Figure 13B |
Center the factory installed refractory retention brackets on the rear base panel so that the bracket is in the middle of each refractory board Figure 13B.
Figure 13A Burner Base, Side Front and Rear 13 to 21 Sections Panel Assembly
Figure 14A |
Base Rear Channel Bolt Holes |
Figure 14B |
Base Rear Channel |
NOTE: Do not install the two lower bolts in the base rear panel, Figure 14A. These holes are used to attach the base rear channel on 6 -12 section rear panels and 13-21, Figure 14B.
Page 15
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
NOTE:The base front panels bolt to the inside of the |
Figure 18 |
Manifold Attachments |
|
front base splice channel, Figure 15. |
|
|
|
Figures 15 |
Base Front Panel Detail |
|
|
Use a spirit level to plumb the front and rear panels before tightening the nuts and bolts, Figure 16. Temporarily attach the manifold brackets and manifold,
Figures 17 and 18.
Figure 16 |
Plumbing Base |
Locate the Burner Box. It is marked with a number from 72724 to 72731. Install three burner tubes in the base, one on each end and one in the middle. Slide the closed end of the burner tube through the slot in the burner base rear panel. The notch in the burner must engage the burner base rear panel, Figure 19.
Figure 19 |
Burner Tube Installation |
Notch
•
•Notch Engaged
Figure 17 |
Manifold Bracket Attachment |
Adjust the manifold and base so the burner tube orifice |
|
|
|
bracket is approximately in the middle of the orifice on |
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|
|
all three burners, Figure 20. |
|
|
|
Figure 20 |
Burner Tube Adjustment |
Page 16
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Bolt the insulation splice panel bracket to the front base |
Figure 22B |
Burner Base Splice Insulation Boards |
|
channel, Figure 21. Install the two insulation boards in |
|
|
|
the spaces between the two front and two rear burner |
|
|
|
base panels. Firmly but carefully press the insulation |
|
|
|
boards in place and insert the nails through the top and |
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|
|
bottom holes, Figure 22A&B. |
|
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Orientate and install splice refractory retainer. Center the |
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|
|
retainer over the splice refractory and mating base |
|
|
|
panels. The retainer should fit snuggly with the flat edge |
|
|
|
on the outside of the base and the angled edge mating |
|
|
|
flush to the refractory. Once insulation boards are |
|
|
|
installed, slide the retention bracket over the top of the |
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|
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base splice as shown in Figures 22C and 22D. Tighten |
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all bolts in base. |
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Figure 21 |
Burner Base Splice Panel Bracket |
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Figure 22C |
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Figure 22D
Figure 22A Burner Base Splice Insulation Boards
NOTE: Check all of the bolts in the base to ensure they are tight before removing the burner tubes and manifold.
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