Smith Cast Iron Boilers GT User Manual

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MODEL GT SERIES

ENERGY STAR

INSTALLATION, OPERATING

AND MAINTENANCE MANUAL

Modulating, Direct Vent, Gas-Fired Condensing Boilers

Natural Or Propane

150,000 to 399,000 Btuh Input

GTIOM-3

see note

gama

WARNING: If the information in this manual is not followed exactly, a ﬁ re or explosion may result causing property damage, personal injury or loss of life.

Do not store or use gasoline or other ﬂ ammable 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 ﬁ re department.

Installation and service must be performed by a qualiﬁ ed installer, service agency or the gas supplier.

WARNING: Installation and service must be performed by a qualiﬁ ed installer, service agency or the gas supplier in accordance with all local and national codes. Failure to comply with this warning can result in a ﬁ re or explosion causing property damage, personal injury or loss of life!

WARNING: It is the responsibility of the homeowner to keep the vent terminal clear of snow and ice. Failure to comply with this warning can result in excessive levels of carbon monoxide causing severe personal injury or death!

ENERGY STAR

INSTALLER: THESE INSTRUCTIONS MUST BE AFFIXED ADJACENT TO THE BOILER.

CONSUMER: RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.

Note: For LP gas use conversion kit: GT82650-1 on GT-150 & 200, GT83017-1 on GT-400

WESTCAST, INC. 260 NORTH ELM STREET WESTFIELD, MA 01085 TEL. (413) 562-9631 FAX (413) 562-3799

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 2

CONTENTS

Before You Start ................................................. page 2

Boiler Ratings & Capacities ...............................page 2

Boiler Location ................................................... page 3

Clearances to Combustible Construction ..........page 3

Combustion Air ..................................................page 4

General Venting Guidelines ...............................page 4

Horizontal Direct Vent Systems .........................page 5

Vertical Direct Vent Systems ............................... page 9

Condensate Drain ............................................page 10

General Plumbing Guidelines .......................... page 11

Primary Loop Plumbing ...................................page 13

Multiple Boiler Primary Loop Plumbing ........... page 13

Secondary Loop Plumbing ..............................page 13

Gas Supply Piping ...........................................page 18

Electrical Wiring ............................................... page 19

Sentry 2100 Controller ....................................page 26

Boiler Set Up ...................................................page 29

Operating Instructions .....................................page 29

Boiler Checking & Adjusting ............................page 33

Gas Pressure Adjustment ................................page 33

Boiler Maintenance .......................................... page 34

Wall Hung Conversion .....................................page 35

Trouble Shooting .............................................page 36

Replacement Parts ..........................................page 41

To obtain the safe, dependable, efficient operation and long life for which this boiler was designed, these instructions must be read, understood and followed.

Direct all questions to your Smith distributor or to the Customer Service Department, 260 North Elm Street, Westﬁ eld, MA 01085. Always include the model and serial numbers from the rating plate of the boiler in question.

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.

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.

The 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-latest revision. In Canada, the installation must be in accordance with the requirements of CSA B149.1 or B149.2 Installation Code for Gas Burning Appliances and Equipment.

BEFORE YOU START

WARNING: This manual must be read and fully understood before installing, operation or servicing this boiler! Failure to follow these instructions could result in a ﬁ re or explosion causing extensive property damage, personal injury or death!

These instructions cover the GT Series gas ﬁ red, direct vent, low pressure, hot water boiler. GT boilers have been design certiﬁ ed by CSA for use with natural and propane gas under the latest edition of ANSI-Z21.13/CSA 4.9, Gas-Fired Low Pressure Steam and Hot Water Boilers.

Each unit has been constructed and hydrostatically tested for a maximum working pressure of 30 psi, 207 kPa, in accordance with Section IV of the ASME Boiler and Pressure Vessel Code. Each boiler has been equipped with a 30 psi, 207 kPa pressure relief valve.

This manual covers the application, installation, operation and maintenance of a GT Series low pressure hot water boiler.

If installed in the Commonwealth of Massachusetts, you MUST FOLLOW the additional instructions contained in Smith’s instruction sheet MA IOM. If you don’t have a copy call your Smith distributor or Smith.

BOILER RATINGS & CAPACITIES

Before undertaking the installation of the GT check the boiler rating plate to ensure that the boiler is the proper size for the job.

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 proximity a suitable outside wall.

High Altitude Operation

The GT boiler is designed to operate to capacity in installations with 2000 ft, 610 m of elevation or less. At elevations higher than 2000 ft, 610 m the unit will de-rate due to the lower air density, see Figure 1.

NOTE: It is the Installers responsibility to check the combustion, and to adjust the combustion in accordance to Operating Instructions Section.

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 3

Figure 1- Input vs Elevation Graph

400

300

)hbM( tupnI

200

100

GT-15 0 GT-200 GT-400

0-2000 3000 4000 5000 6000 7000 8000 9000 10000

Elevation (ft)

WARNING: At elevations greater than 2000 ft, 660 m, the combustion of the GT must be checked with a calibrated combustion analyzer to ensure safe and reliable operation. Consult the Operating Instructions Section for instructions on adjusting the input to provide proper operation. Failure to comply with this warning can result in excessive levels of carbon monoxide causing severe personal injury or death!

BOILER LOCATION

WARNING: The clearances to combustible construction listed in Table 1 must be maintained. Failure to comply with this warning can result in a extensive property damage, severe personal injury or death!

CAUTION: This boiler is designed to operate only in residential and commercial heating systems. It is not intended for:

1. Outdoor installations, or unheated spaces, which can cause freezing.

2. Process heating of potable water, or any other ﬂ uids.

3. Un-pressurized, and gravity feed heating systems.

4. Heating systems with very low pressures or ﬂ ow.

Improper use or installation will seriously damage the boiler, voiding warranty!

1. Locate the boiler in an area that provides good

access to the unit. Keep in mind that servicing may require the removal of jacket panels. Accessibility clearances should take precedence over fire protection clearances. Table 1 lists the minimum clearances for servicing, however 24 in, 610 mm is recommended.

2. An optimum site will be level, central to the hot water piping system and close to an outside wall.

NOTE: This boiler is designed for direct placement on a combustible ﬂ oor. Never install this boiler on carpeting!

3. 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. The boiler location ambient

temperature must be no less than 50°F, 10°C including the condensate line.

4. NEVER store objects on or around the boiler.

5. This boiler may be wall mounted. See the Wall Hung Conversion section listed in the table of contents.

WARNING: Never store combustible materials, gasoline or any product containing ﬂ ammable vapors or liquids in the vicinity of the boiler. Failure to comply with this warning can result in extensive property damage, severe personal injury or death!

WARNING: Liquefied Petroleum, LP, gas is heavier than air; it is imperative that your boiler is not installed in a pit or similar location that will permit heavier than air gas to collect. Local Codes may require appliances fueled with LP gas be provided with an approved means, of removing unburned gases from the room. Check your local codes for this requirement. Failure to comply with this warning can result in extensive property damage, severe personal injury or death!

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 4

Table 1 - Clearances

Combustible Service Clearance Clearance Surface in mm in mm

Front 0 0 24 610 Back 0 0 0 0 Sides 0 0 12 305 To p 0 0 12 305 Bottom - 150 & 200 0 0 12 305 Bottom - 400 0 0 0 0 Flue Pipe - enclosed 2 51 n/a n/a Flue Pipe - in free air 0 0 n/a n/a

COMBUSTION AIR

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. 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 this boiler unless the air intake is connected to the outdoors. Failure to comply with this warning can result in excessive levels of carbon monoxide causing severe personal injury or death!

WARNING: Each boiler must have it’s own intake air system. Common intake air systems are not to be used! Improper installation can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

To operate properly and safely this boiler requires a continuous supply of air for combustion. NEVER store objects around the air inlet!

One of the following materials is to be used for the air intake pipe:

• GT-150 & 200: 3 in, 76 mm, PVC Sch.40 pipe or

Galvanized Steel pipe.

• GT-400: 4 in, 102 mm or 6 in 152 mm, PVC Sch.40

pipe or Galvanized Steel pipe.

See Table 2 for the maximum equivalent air intake system length.

CAUTION: Combustion air contaminated with ﬂ uorocarbons or other halogenated compounds such as cleaning solvents, refrigerants, chloride, ﬂ ouride, bromine or iodine will result in the formation of acids in the combustion chamber. These acids will cause premature failure of the boiler voiding the warranty!

GENERAL VENTING GUIDELINES

WARNING: The vent installation must be in accordance with Part 7, Venting of Equipment, of the latest revision of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 applicable provisions of the local building codes. Improper venting can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

NOTE: Compliance with code requirements doesn’t insure a satisfactory installation; good common sense must also be applied.

WARNING: Each boiler must have it’s own vent system. Common positive pressure vent systems are not to be used! Improper installation can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

Use appropriate adapters to increase the 11⁄2 in,

38 mm air inlet collar to 3 in, 76 mm at the boiler, GT-150 & 200, Figure 2. Use a 2 in, 51 mm to 4 in, 102 mm adapter on the GT-400. Terminate the air inlet system per the instructions found in the venting sections that follow.

Figure 2 - Air Inlet System Attachment

WARNING: Field supplied piping and fittings are required to complete installation. The combustion air and vent pipe and ﬁ ttings must conform to ANSI and ASTM standard D1785 for schedule 40 PVC, D2665 for PVC-DWV, and D2661 for ABS-DWV. Pipe cement and primer must conform to ASTM standard D2564 for PVC or D2235 for ABS. Improper venting can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 5

The GT condensing gas boiler is a high efficiency boiler utilizing induced power venting. It is designed to be vented directly to the outdoors using the venting methods and materials detailed in this section. The vent system must be both gas tight and watertight. All horizontal vent piping must be sloped back to the boiler a minimum of 1/4 in/ft, 21mm/m of vent.

NOTE: Steps must be taken to ensure that condensate does not collect in the venting system or the boiler will not operate properly.

This boiler may be vented using the following materials, but local codes must be followed:

• GT150 & 200: 3 in, 76 mm, PVC Sch.40 solid core pipe, CPVC Sch.40 pipe, AL29-4C Flex Stainless Vent or AL29-4C Rigid Stainless Vent.

• GT-400: 4 in, 102 mm or 6 in, 152 mm, PVC Sch.40 solid core pipe, CPVC Sch.40 pipe, AL29-4C Flex Stainless Vent or AL29-4C Rigid Stainless Vent.

CAUTION: All vent systems must be fully supported by the building structure. The vent connection and vent piping MUST be perfectly aligned to the boiler connection, Figure 3. It MUST NOT APPLY ANY WEIGHT OR LATERAL FORCE TO THE FLUE BOX or the ﬂ ue box will be damaged voiding the warranty!

Table 2 - Vent & Air Intake System Sizing

Model Equivalent Combined Vent & Air Intake Number System Length (see note)

GT-150 105 ft, 32 m GT-200 105 ft, 32 m GT-400 4" - 30 ft, 9 m 6" - 65 ft, 20 m PGT-150 50 ft, 15 m PGT-200 50 ft, 15 m PGT-400 4" - 30 ft, 9 m 6" - 65 ft, 20 m

Note: Subtract 5 ft, 1.5 m, for each 90° elbow except for the vent and air intake elbows. These don’t need to be considered. The length of the air inlet system must never exceed the length of the vent system. The vent system length may exceed the air inlet system length by no more than 20 equivalent ft, 6.1 equivalent m.

HORIZONTAL DIRECT VENT SYSTEMS

Read the information in the GENERAL VENTING GUIDELINES section. It is recommended that two elbows be used, so that the 1/4 in/ft, 21mm/m slope of the horizontal vent system does not affect the vertical plumb of the pipe connected to the boiler, Figure 4.

Figure 4 - Vent System Attachment

Appropriate adapters must be used to increase the 2 in, 51 mm vent collar to 3 in, 76 mm at the boiler, GT-150 & 200, Figure 3. On the GT-400 the 4 in, 102 mm long 4 inch diameter ABS pipe provided with the boiler must be inserted into the exhaust connection on the top of the boiler and tightened in place with the supplied clamp.

Figure 3- Vent Pipe To Boiler Attachment

The maximum combined equivalent vent and intake pipe lengths are listed in Table 2. The length speciﬁ ed is the equivalent vent length added to the equivalent intake length.

When horizontal vent runs exceed 5 ft, 1.5m, they must be supported at 3 ft, 0.9 m, intervals with overhead hangers, 4 ft, 1.2 m for 6" pipe. The vent system must be pitched down, toward the boiler, 1/4 in/ft, 21mm/m. of vent. Structural penetrations must be made using approved thimbles.

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 6

The vent terminal shall not terminate:

• Directly above a paved sidewalk or a paved drive-way

that is located between two buildings, and that serves both buildings;

• Less than 7 ft, 2.1 m above grade where located

adjacent to a paved driveway or public walkway.

• Within 3 ft, 0.9 m, horizontally of a window or door that

can be opened, or non-mechanical air supply inlet to any building.

• Within 6 ft, 1.8 m, of a mechanical air supply inlet to

any building or roof eve containing sofﬁ t openings.

• Above a meter/regulator assembly within 3 ft, 0.9 m,

horizontally of the vertical centerline of the regulator.

• Within 6 ft, 1.8 m, of any gas service regulator vent

outlet.

• Less than 30 in, 762 mm, plus snow allowance above

grade, or any surface that will support snow, ice, or debris. The exhaust must be a minimum of 18 in,

457 mm, above the air inlet, and the air inlet must always be a minimum of 12 in, 305 mm. plus snow allowance above any surface that will support snow. A 24 in, 610 mm, plus snow allowance is highly recommended. Consult your weather ofﬁ ce, for the maximum typical snowfall for your region.

• Underneath a verandah, porch, or deck.

• So situated that the ﬂ ue gases are directed towards

brickwork, siding, or other construction, in such a manner that may cause damage from heat or condensate from the ﬂ ue gases.

• Less than 3 ft, 0.9 m, from an inside corner of an

L-shaped structure including walls and fences. Under normal operating conditions this appliance will produce a plume of water vapor, and should be taken into consideration when selecting an adequate vent terminal location. A 3 ft, 0.9 m, diameter stainless, plastic, or vinyl shield can be used to ﬂ ash the exterior of the residence to protect is from damage.

Consult your weather office for the maximum typical snowfall for your region. For example, in Boston MA the maximum typical snowfall is 12 in, 305 mm. Therefore the inlet must be 24 in, 610 mm, above any surface that will support snow and the exhaust must be 42 in, 1067 mm, above this surface.

For example, if the horizontal separation is 24 in,

610 mm, a minimum vertical separation of 18 in, 457mm, + 12 in, 305mm, = 30 in, 762 mm is required,.

If the horizontal distance is greater than 6 ft, 1.8 m, no additional vertical spacing is required. The vertical separ-ation is never required to be greater then 36 in, 914 mm.

Figure 5 - Horizontal Terminal Locations

305 mm, increase the

Separate Air Intake and Vent Terminals

It is highly recommended that the air intake and vent terminals not be located where they will be exposed to normal prevailing winds. Both terminals must be on the same wall.

The vent terminal must be a minimum of 18 in, 457 mm above the air inlet terminal. The air inlet terminal must always be a minimum of 12 in, 305 mm, plus the snow allowance above any surface that will support snow, however a snow allowance of two feet is highly recommended Figure 5, 6, 7 & 8.

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 7

When penetrating an outside wall the air intake and vent pipes must be constrained as shown in Figure 6. The openings through which the air intake and vent pipes pass must be properly sealed to prevent products of combustion from entering the building.

WARNING: Failure to properly install and seal the air intake and vent system can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

Figure 6 - Wall Penetration Detail

For installations that have to exit the foundation below grade excavate the site as shown in Figure 8 to a point below where the pipes exit the building. Maintain the proper vent clearances as outlined above. Attach the vent and air intake pipes to the outside of the building using special bracket 82075. Ensure that the wall penetrations are properly sealed before backﬁ lling the site.

Figure 8 - Below Grade Installation

In some cases it may be necessary to attach the air intake and vent pipes to the outside wall for added rigidity, Figure 7. If this is the case, special bracket GT-82075 must be ordered for each pipe. Proper clearances must be maintained.

Figure 7 - Air Intake & Vent Pipe Attachment

If required, the air intake and vent systems may be run along an outside wall, Figure 9, providing the following conditions are met:

1. The maximum length on the outside of the building is not more than 20 ft, 6.1 m.

2. All normal termination clearances are maintained.

3. The entire vent system external to the building is insulated using closed cell foamed polyoleﬁ n tubing having a minimum wall thickness of 1/2 in, 13 mm.

4. The air intake and vent systems are supported every 24 in, 610 mm.

5. The air intake and vent systems are sloped 1/4 in/ft, 21mm/m back toward the boiler.

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 8

Figure 9 - External Air Intake and Vent Systems

SUPPORTS EVERY 24 IN

EXHAUST

20 FOOT MAX OUTSIDE USING ONLY 3" PIPE ON THE 150 & 200 AND 4"

INLET

12 IN ABOVE MAXIMUM SNOW LINE

PIPE ON THE 400

The debris screens provided with the boiler must be installed in both the air intake and vent terminals. Install the screens in the outer most opening then glue a 1 in, 25 mm length of pipe into the opening to retain them, Figure 10.

Figure 10 - Debris Screen Installation

Figure 11- Horizontal Concentric Terminal Location

Figure 12 - Vertical Concentric Terminal Location

Concentric Air Intake and Vent Terminal GT-150 & 200 Only

If a concentric terminal is used it must be Smith part number GT-82666 or York part number 1CT0303. The concentric terminal must be located at least 12 in, 305 mm, above the normal snow line, Figure 11. Position the air intake pipe on the top or to the side to prevent rain from entering the boiler, Figure 13.

When terminals from multiple boiler installations exit a common wall the following conditions must apply:

1. If limited to two terminals the horizontal centerline distance must be 4 in, 102 mm, or greater than 24 in, 610 mm, to prevent flue gas recirculation. For more than two terminals located along a horizontal plane, the centerline distance between them must be 24 in, 610 mm, Figure 11.

2. If the terminals are located in a vertical plane the centerline distance between them must be at least 48 in, 1220 mm, Figure 12.

When penetrating an outside wall the concentric terminal must be constrained as shown in Figure 13. The opening through which the concentric terminal passes must be properly sealed to prevent products of combustion from entering the building. The air intake of the boiler must

be connected to the terminal!

WARNING: Failure to properly install and seal the concentric terminal can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 9

Figure 13 - Wall Penetration Detail

The debris screen provided with the boiler must be installed in the concentric terminal as shown in Figure

14.

Figure 14 - Debris Screen Installation

VERTICAL DIRECT VENT SYSTEMS

Read the information in the GENERAL VENTING GUIDELINES section before proceeding.

The GT can be vented vertically directly through the building’s roof or through a dormant chimney used as a chase, Figures 15 & 16. All roof penetrations must be properly ﬂ ashed and sealed.

WARNING: Under no conditions, shall this boiler vent gases directly into a masonry chimney nor can an active chimney be used as a chase. Failure to comply with this warning can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

Consult your weather office for the maximum typical snowfall for your region. For example, in Boston MA the maximum typical snowfall is 12 in, 305 mm. Therefore the inlet must be 24 in, 610 mm, above any surface that will support snow. The exhaust must be 42 in, 1067 mm, above this surface.

Figure 15 - Two Pipe Through the Roof

The horizontal centerline distance between the inlet and exhaust terminals must be a minimum of 4 in, 102 mm. If the horizontal distance between the inlet and exhaust is more than 12 in, 305 mm, increase the vertical separation by the same amount. For example, if the horizontal separation is 24 in, 610 mm, a minimum vertical separationof 30 in, 762 mm, is required, 18 in, 457 mm, + 12 in, 305 mm, = 30 in, 762 mm. If the horizontal distance is greater then 6 ft, 1.8 m no additional vertical spacing is required. The vertical separation is never required to be greater then 36 in, 914 mm.

A dormant chimney can be used as a chase through which the air intake and vent pipes can be run, Figure

16. The chimney must not be connected to a ﬁ replace, water heater or any other heating appliance.

Figure 16 - Two Pipe Using Dormant Chimney

Separate Air Intake and Vent Terminals

The discharge of the vent terminal must point away from the pitch of the roof. The vent terminal must be a minimum of 18 in, 457 mm, above the air inlet terminal. The vent terminal must also be 24 in, 610 mm, above any roof surface within a horizontal distance of 10 ft, 3 m. The air inlet terminal must always be a minimum of 12 in, 305 mm, plus the snow allowance above any surface that will support snow, however a snow allowance of 24 in, 610 mm, is highly recommended Figures 15 & 16.

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 10

Install and seal a rain cap over the dormant chimney opening to prevent water from entering the building. Use only ABS, PVC

sch.40

, CPVC, or AL294C pipe for the air inlet and vent systems as stated previously. Ensure that the air inlet and vent system lengths are within the maximums speciﬁ ed in Table 2.

The debris screens provided with the boiler must be installed in both the air intake and vent terminals. Install the screens in the outer most opening then glue a 1 in, 25 mm, length of pipe into the opening to retain them, Figure 9.

Concentric Air Intake and Vent Terminal GT-150 & 200 Only

If a concentric terminal is used it must be Smith part number GT-82666 or York part number 1CT0303. The concentric terminal must be located at least 24 in, 610 mm, above the normal snow line, Figure 17. The building structure must support the air inlet and vent systems. All roof penetrations must be properly ﬂ ashed and sealed. A dormant chimney can be used as a chase through which the air intake and vent pipes can be run. All previous instructions and warnings apply.

When terminals from multiple boiler installations exit a roof the following conditions must apply:

Figure 18 - Multiple Concentric Through the Roof

CONDENSATE DRAIN

WARNING: The condensate siphon must be connected to the boiler per the following instructions or combustion gases will enter the room. This can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

If limited to two terminals the horizontal centerline distance must be 4 in, 102 mm or greater than 24 in, 610 mm, to prevent flue gas recirculation. For more than two terminals located along a given plane, the centerline distance between them must be 24 in, 610 mm, Figure 18.

Figure 17 - Concentric Through the Roof

This unit produces water as a byproduct of combustion. Much of this water condenses on the heat exchanger and in the venting system. Condensate must be drained from the boiler into a household drain as shown in Figure 19.

Figure 19 - Condensate Piping

NOTE: Check with your municipality, or local gas company to determine if disposal of untreated combustion condensate is permitted. If not, the condensate will have to be neutralized with lime crystals, marble chips or phosphate chips.

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 11

The following are important rules that must be followed when constructing the condensate system:

1. Connect the condensate trap to the drain using

1/2 in, 13 mm, silicone, rubber, reinforced nylon, or PEX tubing. Long runs must be properly pitched

and supported to prevent blockage.

2. Do not use nylon tubing, as it will collapse, blocking

drainage. This could damage the boiler.

Do not seal the opening between the condensate pipe and the condensate drain pipe, Figure 19. In the event of a blocked drain the opening will allow the condensate to overﬂ ow and prevent the boiler from ﬂ ooding.

4. Never have the drain pipe higher than the hole in the

back cabinet, this will ﬂ ood the boiler.

5. Never allow the drain to freeze or become blocked.

This will cause condensate to fill the combustion chamber resulting in a no heat condition and damage to the boiler.

6. NEVER use copper, steel, or galvanized piping in

the construction of the condensate system.

7. When a condensate pump is used or required, select

a pump that is designed for residential furnaces.

GENERAL PLUMBING GUIDELINES

If connecting this boiler to a system containing cast iron radiation, be sure to add a strainer to the system to trap any sediment that may dislodge. Failure to do this could harm the heat exchanger and void the warranty! The use of non-oxygen barrier radiant tubing is acceptable, provided that non-ferrous pipe, valves, and ﬁ ttings are used throughout the entire hydronic system.

CAUTION: All heating system piping must be installed in accordance with the ANSI/ASME Boiler and Pressure Vessel Code, Section IV. All applicable local codes and ordinances must also be followed. If the boiler is installed above any radiation elements it must be fitted with a low water cutoff device installed above the normal boiler water level!

CAUTION: This boiler must have adequate water flowing through it whenever the burner is on. Failure to do this will damage the unit and void the warranty!

CAUTION: All systems must be ﬂ ushed to remove sediment, flux, filings and other foreign matter. Use products such as Fernox “Superﬂ oc” for new installations and CHR “Central Heating Restorer” for retrofits. Also add an inhibitor to the system water to prevent limestone and magnetite deposits from forming and to protect the boiler from galvanic corrosion. An inhibitor such as CHP, “Central Heating Protector” from Fernox is recomended.

The use of non-oxygen barrier radiant tubing is acceptable, provided that non-ferrous pipe, valves, and ﬁ ttings are used throughout the entire hydronic system. Failure to comply with these instructions will seriously damage the boiler, voiding warranty!

CAUTION: The boiler fittings cannot support any weight. The plumbing system must be supported by the building structure. A wrench must be used to hold the boiler ﬁ ttings when installing the heating system piping. Failure to do so can seriously damage the boiler, voiding warranty!

The GT hot water boiler comes from the factory ready to be piped to the heating system. The boiler must be used only in a Primary/Secondary pumping system to avoid cycling problems in systems that have poor ﬂ ow or heating zones with very small capacities.

CAUTION: A 11⁄4 in, 32 mm, primary loop system must be used for GT-150 & 200 models regardless of the conﬁ guration of the secondary system design. A 11⁄2 in, 38 mm, primary loop system must be used for the GT-400. Failure to properly plumb the boiler may void the warranty!

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 12

Understand and follow the plumbing requirements provided in this section. Keep serviceability in mind when installing plumbing around the boiler cabinetry. Install ﬁ ttings that will allow the system to be ﬂ ushed if needed during annual check-ups. Add an inhibitor to the system water to prevent lime and magnetite deposits from forming, and to protect the boiler from galvanic corrosion. A minimum clearance of 1 in, 25 mm must be maintained between heating system pipes and all combustible construction. All heating system piping must be supported by suitable hangers not the boiler. The thermal expansion of the system must be considered when supporting the system. A minimum system pressure of 12 psig, 84 kPa must be maintained.

Hot water boilers are designed to operate with airless water in the system. The GT boiler is provided with a 1/8 in, 3 mm, air vent located on the top of the unit. This air vent is intended to vent the boiler on initial startup. This device will NOT continuously vent air collecting in the primary loop and is not intended to be the primary venting device. The air scoop as shown in Figure 21 is the primary venting location. It is recommended that an additional air scoop be used in the secondary plumbing. If air continues to be a problem an air scrubber must be used.

Pressure Relief Valve

Each boiler is equipped with a 30 psi pressure relief valve that must be piped in accordance with the ANSI/ ASME Boiler and Pressure Vessel Code, Section IV to prevent scalding of persons with hot liquid or vapor in the event of a discharge, see Figure 20.

Support the relief valve discharge piping to prevent strain on the valve body. Leave the open end of the relief valve discharge pipe visible for periodic inspection.

NOTE: The discharge pipe diameter must be the same at the relief valve output diameter. Never restrict the outlet relief valve.

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!

Figure 20 - Relief Valve Piping

NOTE: Only inhibited propylene glycol solutions should be used if freeze protection is required. Avoid using mixtures greater than 30%, unless the size of the boilers’ circulator(s) is increased accordingly. Under no circumstances should a 50% mixture be exceeded.

Non ASME GT-150 All ASME Models

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 13

Low Water Cut Off, LWCO

If a LWCO is used ensure that the water line of the “Low Water Cutoff” is at least 6 in, 152 mm, above the top of the boiler, Figure 21. It is recommended that the LWCO be situated so that it can be tested without removing water from the boiler. Tri-cocks and a gauge glass are highly recommended. Valves shall not be installed between the LWCO and the boiler. Use an air vent if installed as per our diagram to be used as a vacuum breaker and to eliminate air upon ﬁ lling.

Figure 21 - LWCO & Air Vent Piping

Figure 22 - Boiler Head Loss

GT-150 GT-200 GT-400

daeH fo teeF

2 4 6 8 10 12 14 16 18 20 22 24 26 27

GPM us

Table 3 lists the recommended circulators for use as the primary and indirect loop pumps.

Figure 23 shows the proper way to plumb a primary loop for single boiler installations.

MULTIPLE BOILER PRIMARY LOOP

Figure 24 shows the proper way to plumb a primary loop for multiple boiler installations.

SECONDARY LOOP PLUMBING

Figures 25 and 26 show some typical primary/ secondary piping systems. It is the responsibility of the installing contractor to determine which system best meets the need of the installation. Contractor modiﬁ cations to these instructions may be required, based upon the existing

PRIMARY LOOP PLUMBING

This low mass boiler requires a continuous minimum water ﬂ ow for proper operation. The heat exchanger in this boiler is more restrictive than a conventional boiler. The system pump must be sized to overcome the head loss of the boiler, Figure 22. Greater consideration must be given to the capabilities of the circulating pump(s) in the primary-loop. This includes the pump used for an indirect tank.

Table 3 - Recommended Primary and Indirect Loop Circulators

Minimum Max. Temp. Minimum Primary & Restriction Flow Rise Indirect Pump Size Model Head Loss GPM, L/s °F, °C

GT-150 7 ft at 6 GPM, 2.1 m at 0.4 L/s 6, 0.4 45, 25 NRF-33 UP 26-64 0010

GT-200 10 ft at 8 GPM, 3 m at 0.5 L/s 8, 0.5 45, 25 PL-36 UP 26-99 0011

GT-400 10 ft at 20 GPM, 3 m at 1.25 L/s 13, 0.8 57, 45 PL-36 UP 26-99 0011

piping and system design.

B&G Grundfos Taco

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 14

Figure 23 - Single Boiler with Indirect Hot Water Heater

NOTES:

1. All piping and pumps must be supported so that no loads or stresses are applied to boiler heat exchanger. To make boiler service easy use Unions or ﬂ exible Vibration Isolation Kit.

2. This boiler is provided with a 1/8" vent that is not intended for continuous system venting.

3. For continuous system venting use a cast iron air scoop, for excessive air conditions use a Spirovent. Do not ﬁ re boiler until all air is purged from the system piping. Heat exchanger damage caused by air is not covered by warranty.

4. See Table 3 for boiler pump ﬂ ow requirements. This pump is wired to terminals C1-L2.

5. See Table 3 for Indirect Water Heater pump ﬂ ow requirements. This pump is wired to terminals AP-L2.

6. Set pressure reducing valve to 12 PSI.

7. Use 30 psi relief valve max. Locate where discharge will not cause injury or damage. Follow local codes.

8. Add an inhibitor to protect system. (CHP from Fernox)

9. Boiler circuit piping must be sized large enough to handle maximum ﬂ ow through unit.

10. Suggested piping. When installing an indirect water heater consult manufacturer’s manual for full details.

11. Do not install any valves between the Vacuum Relief valve and the tank.

12. Do not operate boiler with service valves closed isolating the boiler from the expansion tank.

13. Failure to follow these instructions will result in heat exchanger damage: All ﬂ ux and contaminants must be ﬂ ushed from piping before connecting boiler. Do not connect this boiler to older systems with cast iron radiation without installing a ﬁ ne particulate separator. TYP: Spirotrap Junior Model TDN 125 FT. Do Not use non-oxygen barrier radiant tubing.

Notice: This drawings show suggested piping conﬁ guration and valving. Check with local codes and ordinances for speciﬁ c requirements.

Pump

Gate Valve Backflow-Prevention

Ball Valve

Pressure

Reducing

Valve

Check Valve

Pressure

Relief Valve

Thermometer

Union Automatic

Air Vent

Heating

Load

Drain Valve

(Typ.)

Device

Differential Pressure

Bypass Valve

Spirotrap

Fine Particulate

Separator

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 15

Figure 24 - Multiple Boiler Installation

NOTES:

1. All piping and pumps must be supported so that no loads or stresses are applied to boiler heat exchanger. To make boiler service easy use Unions or ﬂ exible Vibration Isolation Kit.

2. This boiler is provided with a 1/8" vent that is not intended for continuous system venting.

3. For continuous system venting use a cast iron air scoop, for excessive air conditions use a Spirovent. Do not ﬁ re boiler until all air is purged from system piping. Heat exchanger damage caused by air is not covered by warranty.

4. See Table 3 for boiler pump ﬂ ow requirements. This pump is wired to terminals C1-L2.

5. Indirect Water Heater pump is wired to terminals AP-L2.

6. Set pressure reducing valve to 12 PSI.

7. Use 30 psi relief valve max. Locate where discharge will not cause injury or damage. Follow local codes.

8. Add an inhibitor to protect system. (CHP from Fernox)

9. Boiler circuit piping must be sized large enough to handle maximum ﬂ ow through unit.

10. Do not operate boiler with service valves closed isolating the boiler from the expansion tank.

11. Failure to follow these instructions will result in heat exchanger damage. All ﬂ ux and contaminants must be ﬂ ushed from piping before connecting boiler. Do not connect this boiler to older systems with cast iron radiation without installing a ﬁ ne particulate separator. TYP: Spirotrap Junior Model TDN 125 FT. Do not use non-oxygen barrier radiant tubing.

Notice: This drawings show suggested piping conﬁ guration and valving. Check with local codes and ordinances for speciﬁ c requirements.

Pump

Gate Valve Backflow-Prevention

Ball Valve

Pressure

Reducing

Valve

Check Valve

Pressure

Relief Valve

Thermometer

Union Automatic

Air Vent

Heating

Load

Drain Valve

(Typ.)

Device

Differential Pressure

Bypass Valve

Spirotrap

Fine Particulate

Separator

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 16

Figure 25 - Multiple Zones Using Circulators

NOTES:

1. All piping and pumps must be supported so that no loads or stresses are applied to boiler heat exchanger. To make boiler service easy use Unions or ﬂ exible Vibration Isolation Kit.

2. This boiler is provided with a 1/8" vent that is not intended for continuous system venting.

4. See Table 3 for boiler pump ﬂ ow requirements. This pump is wired to terminals C1-L2.

5. Indirect Water Heater pump is wired to terminals AP-L2.

6. Set pressure reducing valve to 12 PSI.

7. Use 30 psi relief valve max. Locate where discharge will not cause injury or damage. Follow local codes.

8. Add an inhibitor to protect system. (CHP from Fernox)

9. Boiler circuit piping must be sized large enough to handle maximum ﬂ ow through unit.

10. Do not operate boiler with service valves closed isolating the boiler from the expansion tank.

11. Failure to follow these instructions will result in heat exchanger damage: All ﬂ ux and contaminants must be ﬂ ushed from piping before connecting boiler. Do not connect this boiler to older systems with cast iron radiation without installing a ﬁ ne particulate separator. TYP: Spirotrap Junior Model TDN 125 FT. Do Not use non-oxygen barrier radiant tubing.

Notice: This drawings show suggested piping conﬁ guration and valving. Check with local codes and ordinances for speciﬁ c requirements.

Expansion

Tan k

Pump

Zone

Valve

Ball Valve

Check Valve

Automatic

Air Vent

Heating

Load

Drain Valve

(Typ.)

Differential Pressure

Bypass Valve

Spirotrap

Fine Particulate

Separator

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 17

Figure 26 - Multiple Zones Valves with Bypass Valve

Note: Velocity noise may be a problem when the entire output of the system pump is ﬂ owing through the zone with the highest pressure drop. Adjust the differential bypass valve to eliminate noise.

NOTES:

1. All piping and pumps must be supported so that no loads or stresses are applied to boiler heat exchanger. To make boiler service easy use Unions or ﬂ exible Vibration Isolation Kit.

2. This boiler is provided with a 1/8" vent that is not intended for continuous system venting.

4. See Table 3 for boiler pump ﬂ ow requirements. This pump is wired to terminals C1-L2.

5. Indirect Water Heater pump is wired to terminals AP-L2.

6. Set pressure reducing valve to 12 PSI.

7. Use 30 psi relief valve max. Locate where discharge will not cause injury or damage. Follow local codes.

8. Add an inhibitor to protect system. (CHP from Fernox)

9. Boiler circuit piping must be sized large enough to handle maximum ﬂ ow through unit.

10. Do not operate boiler with service valves closed isolating the boiler from the expansion tank.

Notice: This drawings show suggested piping conﬁ guration and valving. Check with local codes and ordinances for speciﬁ c requirements.

Expansion

Tan k

Pump

Zone

Valve

Ball Valve

Check Valve

Automatic

Air Vent

Heating

Load

Drain Valve

(Typ.)

Differential Pressure

Bypass Valve

Spirotrap

Fine Particulate

Separator

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 18

GAS SUPPLY PIPING

The GT hot water boiler comes from the factory ready to be piped to the gas supply. The National Fuel Gas Code, ANSI Z223.1/NFPA 54 and local codes for gas piping requirements and sizing must be followed. If for any reason the boiler is not for the type of gas available at the installation site, call the nearest Smith distributor to resolve the problem.

Figure 27 depicts the proper way to connect the boiler to the gas supply piping. The manual shut-off valve MUST be installed in the supply piping. It should be approximately 5 ft, 1.5 m, above the ﬂ oor. Provide a sediment trap/drip leg at the bottom of the vertical section of the gas supply pipe. A ground joint union should be installed between the boiler gas controls and the supply piping. Each of these items is needed to ensure long life and ease of servicing. Always use a pipe sealant that is suitable for use with LP gas. Flexible gas piping is recommended if accepted by the local codes. Make sure the gas piping doesn’t hinder boiler access.

CAUTION: Always use a wrench on the gas valve body when making gas connections to it. Never overtighten the piping entering the gas valve body or the gas valve will be damaged voiding the warranty!

CAUTION: The gas piping must be properly supported by the building structure and not by the boiler or the gas valve will be damaged voiding the warranty!

Figure 27 - Gas Supply Piping

Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests speciﬁ ed in ANSI Z21.13/CSA 4.9. 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!

Table 4 - Gas Pipe Capacity

Nominal Iron Pipe 10' 20' 30' 40' 50' 60' 80' 100' 150' Size

3/4" 278 190 152 130 115 105 90 79 64

1" 520 350 285 245 215 195 170 150 120

1 1/4" 1050 730 590 500 440 400 350 305 250

1 1/2” 1600 1100 890 760 670 610 530 460 380

Note: Maximum pipe capacity in ft3/hr is based on a 0.60 speciﬁ c gravity

gas at a pressure of 0.5 psig and a 0.3" WC pressure drop.

Pipe Length

Gas Pipe Capacity (ft3/hr)

Table 5 - Equivalent Pipe Length Chart

Nominal Iron Pipe (branch ﬂ ow) (full port) Size

3/4" 2.06 4.12 0.48 1.25

1" 2.62 5.24 0.61 1.60

1 1/4" 3.45 6.90 0.81 2.15

1 1/2" 4.02 8.04 0.94 2.50

Tee Gate Valve

90°

Equivalent length of pipe ﬁ ttings in feet

Type of Pipe Fitting

Gas Cocks

Table 4 should be used to ensure that the gas supply piping is sized properly. If more than one appliance is supplied by the same supply pipe, the piping must be sized based on the maximum possible demand. Do not neglect the pressure drop due to pipe ﬁ ttings. Table 5 should be used in conjunction with Table 4 to ensure that the gas supply piping is sized properly.

Whenever the gas supply piping is pressure tested the boiler gas controls must be protected. If the test pressure is equal to, or less than 1/2 psi, 3.5 kPa, isolate the boiler by closing it’s manual shut off valve, see Figure 27. If the test pressure is greater than 1/2 psi, 3.5 kPa, disconnect the boiler and it’s individual shut-off valve from the gas supply piping.

WARNING: Failure to protect the gas valve from excessive pressure can damage the gas valve which can cause a ﬁ re or explosion!

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 19

ELECTRICAL WIRING

CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation!

The electrical connections to this boiler must be made in accordance with all applicable local codes and the latest revision of the National Electrical Code, ANSI/ NFPA-70. Install a separate 120 volt 15 amp circuit for the boiler, Figures 28 and 29. A properly rated shutoff switch should be located at the boiler. The boiler must be grounded in accordance with the authority having jurisdiction, or if none, the latest revision of the National Electrical Code, ANSI/NFPA-70. Line voltage ﬁ eld wiring of any controls or other devices must conform to the temperature limitation of type T wire at 95°F, 35°C, above room temperature.Use copper conductors with a minimum size of #14 awg. Low voltage wiring must not be less than #18 awg with a neoprene, thermoplastic or other equivalent insulation having a minimum insulation thickness of 0.012 in, 3 mm.

Schematic and ladder diagrams of the boilers wiring are shown in Figures 33 & 34.

Before supplying 120 volts to the boiler, do a continuity check between all the wires and the ground to make sure that there are no electrical shorts that could damage the Sentry 2100 board.

Never use magnetic tip screwdriver near the Sentry

2100.

Verify that the wires connected to the Sentry TC and AC terminals are not grounded, or have any voltage applied to them, or voltage to ground - dry contact closure only.

Ensure that the probe wire is not damaged.

CAUTION: Damage to the electrical system components caused by improper wiring will void the warranty!

Thermostat Installation

ALWAYS follow the instructions included with the thermostat to be used to control the boiler. Proper location of the thermostat will ensure efﬁ cient trouble-free operation of the boiler. Mount the thermostat to an inside wall at a height approximately ﬁ ve feet above the ﬂ oor.

CAUTION: The contact capacity of outputs C1 or A is 3 amps with a maximum inrush of 6 amps. If the amp draw of the pumps exceeds these maximums, a pump controller, or isolation relay must be used to prevent damage to the boiler. Damage caused by improper wiring will void the warranty!

Figure 28 - Basic Heating System Wiring

Avoid placing the thermostat in areas that will not provide

an accurate measurement of the room temperature. Locating the thermostat behind a door, in an alcove, close to a source of thermal radiation or in a drafty area will cause poor or sporadic heating.

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 20

Figure 29 - Basic Heating System and Indirect Tank Wiring

Multiple 4 Wire Zone Valves

Figure 30 shows the basic multiple zoned system uses normally closed four (4) wire zone valves. This wiring system is used with the piping shown in Figure 26.

When there is a call for heat the room thermostat closes the circuit to the zone valve motor, thus opening the zone valve. When the zone valve is opened, the end switch closes the circuit between terminals T and C on the Sentry 2100 control. The Sentry 2100 provides power to the primary and secondary pumps via terminal C

. Once

these pumps are on, the burner ﬁ res.

Once the room thermostat is satisﬁ ed, it breaks power to the zone valve motor. The end switch opens the circuit between terminals T and C shutting down the pumps and the burner.

Multiple Zones w/ Taco Valve Controller Models ZVC403 to ZVC 406

Figure 31 shows the basic multiple zoned system using normally closed 2, 3 or 4 wire Taco zone valves. This wiring system is used with the piping as shown in Figure

26.

When there is a call for heat the room thermostat closes the circuit between the TT terminals on the Taco zone controller. The controller energizes the appropriate zone valve and closes the circuit between terminals T and C on the Sentry 2100 control. The Sentry 2100 provides power to the primary and secondary pumps via terminal C1.

Once these pumps are on, the burner ﬁ res.

Once the room thermostat is satisﬁ ed, it breaks power to the zone valve motor. The end switch opens the circuit between terminals T and C shutting down the pumps and the burner.

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 21

Figure 30 - Multiple 4 Wire Zone Valves

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 22

Figure 31 - Multiple Zones w/ Taco Valve Controller, Models ZVC403 to ZVC 406

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 23

Multiple Zone Pump Controller Models Taco SR504, Argo ARM 861 Series

Figure 32 shows the basic multiple zoned system using circulating pumps. This wiring system is used with the piping as shown in Figures 25.

When there is a call for heat the room thermostat closes the circuit between the TT terminals on the pump controller. The controller energizes the appropriate circulating pump and closes the circuit between terminals T and C on the Sentry 2100 control. The Sentry 2100, provides power to the primary pump via terminal C1. Once these pumps are on, the burner ﬁ res.

Figure 32 - Multiple Zone Pump Controller, Models Taco SR504, Argo ARM 861 Series

Once the room thermostat is satisﬁ ed, it breaks power to the TT terminal of the pump controller de-energizing the XX contacts. The circuit between terminals T and C opens shutting down the pumps and the burner.

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 24

Figure 33 - Boiler Ladder Diagram

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 25

Figure 34 - Boiler Connection Diagram

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 26

SENTRY 2100T CONTROLLER

CAUTION: The T4.0 controller can only be used on the GT-400 and the T2.0 on the GT-150 & 200. Misapplication of the controller will result in improper boiler operation.

The Sentry 2100T controller is the central controller for the GT boiler. The Sentry handles all of the combustion logic, along with the energy management functions. The Sentry 2100T operates in two different modes, Conventional or Reset, see Figures 35 & 36. The mode is automatically determined by the presence of the outdoor sensor. When the Sentry 2100T detects the presence of the outdoor sensor the controller will operate in the Reset Mode. If the outdoor sensor is not installed, the controller will operate in the Conventional Mode.

NOTE: If the outdoor sensor is connected after the boiler has been started power to the boiler must be shut off and then turned back on.

Boiler Modulation

The GT boiler employs a pneumatic modulation system. This modulation system increases or decreases the speed of the blower to meet the heating demand. The gas valve pressure regulator senses the air pressure and adjusts the gas ﬂ ow to ensure correct combustion. The term “Set Point” is used to indicate the desired temperature that the GT will maintain by increasing or decreasing the input.

Indirect Water Heaters

The Sentry 2100 comes with an input and output for a 120-volt indirect pump. When the A and C terminals are closed, dry contact, the boiler will go immediately to indirect domestic mode, whereby the indirect pump is activated, and the boiler will modulate to the LO setpoint.

Sentry Display

The Sentry 2100T contains four green lights that illuminate to indicate the boilers state of operation, Figure 37.

Figure 37 - 2100T Display Screen

Burner/Bruleur - Indicates that the ignition system is

activated.

Circ. - Indicates that the heating pump is energized.

Circ. Aux.- Indicates a call for DHW, and Indirect pump

or 3-way valve is activated.

Thermostat Demand - Indicates that terminals T-C are closed, iniating a call for heat.

The LED screen will display one of four values. A light will illuminate above the function to indicate what information is being displayed.

Water Temp - Indicates that the display is showing the boiler water temperature.

Air - if the air sensor is used. When illuminated, indicates that the display is showing outdoor air temperature.

Gas Input Value - Indicates the current input level. Figure 38 must be used to determine the actual input. GT-150 use 46 to 240, GT-200 use 40 to 240 and GT-400 use 35 to 195.

DHW Temp. - indicates that there is a call for domestic hot water.

Figure 35 - Conventional Mode Operation Chart

T-C & A-C Open T-C Closed & A-C open T-C Closed & A-C Closed T-C Open & A-C Closed Condition Standby Set Point — HI L0 L0 Burner On — HI - DIF LO-10 LO-10 Burner Off — HI + 10 200°F 200°F Heat Circ. Off On Off Off Aux. Circ. Off Off On On

Heating Only Domestic Only Domestic Only

Figure 36 - Reset Mode Operation Chart

T-C & A-C Open T-C Closed & A-C open T-C Closed & A-C Closed T-C Open & A-C Closed

Condition Standby Heating Only Domestic Only Domestic Only Set Point Burner On — HI Burner Off — HI Heat Circ. (C1) Off On Off Off Aux. Circ. (Ap) Off Off On On

— HI

Calc.

L0 L0

Calc

- DIF LO-10 LO-10

Calc

+ 10 200°F 200°F

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 27

Figure 38 - Input Conversion Chart

400

350

300

)s'000( UTB

250

200

150

100

240 215 190 165 140 115 90 65 48 40

Display Data - Input conversion chart

LED Dis pl ay

Setting Sentry 2100T control

Programming is accomplished by a series of three push buttons located on the bottom side of the control. To enter the programming mode, press the function key once, “RUN” should be displayed on the screen. To scroll through the various menu options depress ↑. To alter the value of a menu option press “Function” once while the menu option is displayed, and the current value will be displayed, then use ↑ for up, and ↓ for down, until the desired value is obtained. To enter the selected value press “Function”, which will return to the menu and store the new setting. When all desired values are set, scroll to the “RUN” menu option, and press Function, which exits the Programming Mode and initiates normal operation. If the control is left in the Program Mode longer than 30 seconds without receiving any input the unit will turn off. Press “Function” once to continue programming or to restart boiler operation.

Below is a list of functions and a description of what they control:

RUN - Stores Values & initiates LO - Boiler Setpoint for DHW, 80 - 200°F, 27 - 93°C HI - Boiler Setpoint for Heating, 80 - 200°F, 27 - 93°C DIF - Differential, 1 - 40°F, -17°C - 4°C RES - Sets Outdoor Reset Curve Slope, 70°F, 21°C to HI SFS - Sets Starting Gas Input Value, 60 to 100

GT150 & 200 is 60 to 100 GT-400 is 45 to 90

HFS - Sets Highest Gas Input Value, 100 to 240

GT-150 & 200 is 100 to 240 GT-400 is 90 to 195

LFS - Sets Lowest Gas Input Value, 40 to 100

GT-150 & 200 is 40 to 100 (see note) GT-400 is 35 to 90

GT-150 GT-200

GT-400

Recommended Settings

When programming the Sentry 2100T determine what the hottest boiler temperature required for the coldest day will be. This will be the HI SETTING. If an indirect tank is used for domestic hot water, DHW, determine the minimum boiler temperature required to ensure an adequate supply of hot water. This is the LO SETTING. The LO SETTING is only used during a call for DHW, when A and C terminals are closed. Set the LO to the temperature required for the Indirect Water Heater. 140 °F, 60°C or at least 30°F, -1°C higher than the indirect Aquastat is recommend.

WARNING: Proper control settings must be used to prevent water supplied for domestic use from exceeding 130°F, 54°C or a scald injury will occur! When higher water temperatures are required for appliances such as a dishwasher, a mixing valve or some other tempering means must be installed. Households with small children may require water temperatures less than 120°F, 49°C. Local codes must be complied with!

Table 6 - Recommend System Temperatures

Hi Dif RES System °F, °C °F, °C °F, °C

Finned Tube Baseboard 190, 88 20, 11.7 85, 29 Cast Iron Radiators 150, 66 20, 11.7 85, 29 Radiant 130, 54 20, 11.7 85, 29

Outdoor Sensor (10K)

The outdoor sensor should be installed to take advantage of the energy saving features of the Sentry Controller. Install the sensor on the north, or coldest side of the building out of direct sun. It must be at least 10 ft, 3 m from the vent terminal or other source of heat.

NOTE: LFS must not be set below 48 on the GT150 model. To start the control operation return to “RUN” on the menu and press “Function”. Normal operation will begin.

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 28

Determining Reset Temperature HI

Calc

Once the Sentry 2100T control identiﬁ es the presence of a good outdoor sensor, the control will automatically reduce the HI setting based upon the outdoor temperature. For example, if Hi = 200°F, 93°C, RES = 70°F, 21°C and the Air Temperature = 32°F, 0°C, the HI setpoint, HI

, would be calculated as follows:

Calc

RESET RATIO = (High Setting - RES)/RES = (200°F, 93°C - 70°F, 21°C) /70°F, 21°C = 1.85

RESET TEMPERATURE HI

Calc

=[(RES-Outdoor Air) x Reset Ratio] + RES =[(70°F, 21°C - 32°F, 0°C) x 1.85] + 70°F, 21°C =[70.6°F, 21°C] + 70°F, 21°C =140.6 F, 42°C

Figures 39 - Reset Curve For Res = 85 °F, 29°C

NOTE: The design temperature is 0°F, -18°C outside air, so at 0°F, -18°C or less, the hi setting is used, and not surpassed.

Figures 39 & 40 are examples of reset temperatures

based upon different set points and outdoor air temperatures. The vertical axis is the water temperature that the boiler will maintain and is also the Hi setting of the Sentry 2100T control. The Horizontal axis is the outdoor air temperature.

Figures 40 - Reset Curve For Res = 70 °F, 21°C

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 29

BOILER SET UP

NOTE: Before starting the boiler, turn off the electrical supply going to it. Make sure that gas is available at the gas valve inlet. Open the valves in the hot water return and supply piping. Failure to take these precautions will prevent the boiler from operation properly.

Fill the boiler and all of the radiation with water. Make sure that the system is completely purged of air, see GENERAL PLUMBING GUIDELINES.

Review these instructions and make sure that the boiler installation complies with ALL of the instructions up to this point.

OPERATING INSTRUCTIONS

WARNING: Before operating read and understand the instructions contained in this manual. Do not attempt to operate this boiler if it has not been installed in accordance with the guidelines set forth in this manual. Read and fully understand the operating instructions in the “For Your Safety Read Before Operating” section of this manual. Failure to comply with this WARNING could result in a ﬁ re or explosion causing severe personal injury or death!

Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control that has been under water.

NOTE: The GT was tested with Natural Gas having a heating value of 1020 BTU per cubic foot. For areas with lower heating values, a combustion test is required to obtain optimum operation.

WARNING: The input Screw MUST NEVER BE ADJUSTED without verifying proper combustion with a calibrated combustion analyzer. Failure to comply with this warning can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

Table 7 contains the range for the CO, CO2 and NOx that should be in a ﬂ ue gas sample of a properly operating boiler at maximum input.

Table 7 - Normal Flue Gas Composition

Natural Gas Propane

Carbon Dioxide CO2 % 8-9.5 9-10.5 Carbon Monoxide CO ppm 25-175 25-175 NOX ppm 10-50 10-50 Note: At maximum fan speed of 240 on the Sentry display

Should overheating occur or the gas supply fail to shut off, do not turn off or disconnect the electrical supply to the pump. Instead, shut off the gas supply at a location external to the appliance.

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 30

The gas supply pressure to the boiler while running at maximum rate must be between 4 to 9 in, 102 to

229 mm, W.C. for natural gas installations; 9 to 12 in, 229 to 305 mm, W.C. for propane installations. This pressure

can be measured on the gas valve using a manometer, Figure 41 or 42. Ensure that the regulator is capable of maintaining this pressure under all operating conditions. The gas valve is also equipped with a manifold pressure port, Figure 41 or 42.

Figure 41 - Gas Valve Layout, GT-150 & 200

Figure 42 - Gas Valve Layout, GT-400

Manifold Pressure

Line Pressure

Ignition System

A. Connect a manometer to the line pressure port

shown in Figure 41 or 42. Make sure that the gas supply piping has been purged of air and that all gas joints up to the gas valve have been thoroughly checked for leaks. Wait at least ﬁ ve minutes for any gas to dissipate before turning on the electrical power.

B. Read, understand and follow the operating

instructions below.

C. Raise the thermostat at least 5 degrees above the

room temperature. The boiler should enter the prepurge mode before energizing the silicon carbide igniter. Once the igniter is hot, the main gas valve will open and the burner should light. If the burner fails to light the system will make three more ignition attempts. If the burner has not lit after the last ignition try, the gas valve will close and the system will go into lock out. DO NOT attempt to reset the system until the ignition system has been inspected and the problem resolved. Once the problem has been resolved and 5 minutes have passed since the last ignition attempt, reset the system by turning the thermostat to it’s lowest setting and then back to where it was or by momentarily interrupting the electrical power to the boiler.

D. With the burner in operation close the manual shutoff

valve in the gas supply line. As soon as the burner ﬂ ame goes out, open the manual shutoff valve. A normal ignition sequence should take place.

Input Screw

E. With the burner in operation, interrupt the power to the

control circuit by lowering and raising the thermostat. A normal ignition sequence should follow.

F. To test the ignition safety shutoff device, close the

manual shutoff valve in the gas supply line. Within 6 seconds of main burner ﬂ ame extinction, the main gas valve solenoid should close with an audible noise. The igniter should glow and make three attempts at ignition. After unsuccessfully attempting to light the burner the ignition module should lock out.

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 31

Figure 43 - Operational Flow Chart

Energizes 3 way

diverter valve

Energizes Primary

Pump (C1)

Error ASC

24 Volt signal

to blower

Error ASO

Sentry 2100

Modulates fan based

upon setpoint and

programming

120v Power

Applied

Combi model

Open

Hi pressure

N. C. switch on

GT 400 only

Igniter warm-up

5 seconds

Combi or

indirect

Indirect

Water

Heater

Closed

Power to ignitor

120v from S1

Power to Gas valve

Displays version

t2.0 or t4.0

Indirect thermostat or flow

switch closes A-C

(Call for Domestic)

Energizes Indirect Pump

(Ap) turns off C1

Closed

Open

Closed

NONC

Prepurge

Air

Switches

Open

Greater than 1.0 microA

Sentry 2100

Fan to SFS (75)

IGNITION MODULE

S1 L1 L2 S2 W MV GND

Boiler in

standby Mode

Awaiting

Input

Sentry 2100

Flame Probe

Signal <1 microA

Thermostat End switch

or relay closes T-C

(Call for Heat)

Energizes Primary

Pump (C1)

(Call for Ignition)

Sentry 2100

24 V

Manifold & Stack Limit

(GT 150 & GT 200)

Manifold Limit & Flow

Switch

(GT 400)

24 V

Three retries

for flame

Less than

1.0 microA

Call for flame ends

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 32

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING: If you do not follow these instructions exactly, a ﬁ re or explosion may result causing property damage, personal injury or loss of life.

A. This appliance does not have a pilot. It is equipped

with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

B. BEFORE OPERATING smell all around the

appliance area for gas. Be sure to smell next to the ﬂ oor because some gas is heavier than air and will settle on the ﬂ oor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not tough any electric switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas suppliers instructions.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Turn off all electric power to the appliance.

3. Set the thermostat to lowest setting.

4. This appliance is equipped with an ignition device,

which automatically lights the burner. Do not try to light the burner by hand!

• If you cannot reach your gas supplier, call the ﬁ re department.

C. Use only your hand to push in or turn the gas

control knob. Never use tools. If the knob will not push in or turn by hand, don’t try to repair it, call a qualiﬁ ed service technician. Force or attempted repair may result in a ﬁ re or explosion.

D. Do not use this appliance if any part has been

under water. Immediately call a qualiﬁ ed service technician to inspect the appliance and to replace any part of the control system and any gas control that has been under water.

5. Remove control access panel.

6. Turn the manual gas supply shut off valve clock-

wise to the full “OFF” position.

7. Wait ﬁ ve (5) minutes to clear out any gas. Then

smell for gas, including near the ﬂ oor. If you then smell gas STOP! Follow “B” in the safety information above. If you don’t smell gas, go to the next step.

GAS IN

MANIFOLD PRESSURE

out

INPUT SCREW

LINE PRESSURE

TO TURN OFF GAS TO APPLIANCE

1. Turn off all electric power to the appliance.

2. Set the thermostat to lowest setting.

3. Remove control access panel.

8. Turn the manual gas supply shut off valve

counter-clockwise to “ON”.

9. Replace control access panel.

10. Turn on all electric power to the appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the instruct-

tions “TO TURN OFF GAS TO APPLIANCE” and call your service technician or gas supplier.

4. Turn the manual gas supply shut off valve clock-

wise to the full “OFF” position.

5. Replace control access panel.

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 33

BOILER CHECKING & ADJUSTMENT

Input Rate

Gas appliances are rated based on sea level operation with no adjustment required at elevations up to 2000 ft, 610 m. At elevations above 2000 ft, 610 m, input ratings should be reduced by 4% for each 1000 ft, 305 m, above sea level. Check the input rate as follows:

NATURAL GAS:

1. Turn off all other gas appliances that use the same gas meter as the boiler.

2. Call the gas company for the gas heating value.

3. Start the boiler and let it run for 15 minutes.

4. Using the gas meter and a stopwatch, clock the time that it takes to burn 10 cubic feet of gas and divide the time by 10.

5. Insert the heating value and the time, in seconds, into the formula below.

Input Rate = Heating Value(Btu/ft3)(3600 s/hr) Flow Rate(s/ft3)

EXAMPLE: If the heating value = 1000 Btu/ft and the ﬂ ow rate = 18 s/ft

Input Rate = (1000 Btu/ft3)(3600 s/hr) 18 s/ft

Input Rate = 200,000 Btu/hr

If the computed rate deviates by more than 5% from the rated input value of the unit adjust the gas valve pressure according to the GAS PRESSURE ADJUSTMENT instructions that follow.

Gas Pressure Adjustment

Optimum results are obtained when the boiler is operated at its full input rating. If adjustment is necessary the following steps must be followed:

1. Connect a ﬂ ue gas analyzer to the vent pipe.

2. Rotate the input adjustment screw clockwise to decrease the manifold pressure, counterclockwise to increase it, Figure 41 or 42. The input screw on the GT-150 & 200 is a multi turn needle valve. From fully open to fully closed is approximately 17 turns. A typical adjustment is 0 to 1 turn for natural gas, 0 to 3 turns for LP. The input screw on the GT-400 turns a geared ball valve with a 4 to 1 ratio. Two turns will take the valve from fully open to fully closed. 0 to 1/4 turn is a typical adjustment. Never force the input adjustment screw or the gas valve will be damaged!

3. For natural gas the CO

reading should fall between

8% and 9.5% with a CO reading of less than 175 ppm air free. For LP gas the CO2 reading should fall between 9% and 10.5% with a CO reading of less than 175 ppm air free.

Main Burner Flame

A properly adjusted main burner ﬂ ame will produce a tight blue ﬂ ame pattern about 1/2 in, 13 mm, tall from the burner’s surface, Figure 44. A yellow ﬂ oating or tall stringy ﬂ ame is not normal and must be corrected.

WARNING: Yellow, ﬂ oating ﬂ ames indicate a lack of combustion air. DO NOT operate the boiler until the problem is solved or severe personal injury or death may occur!

Figure 44 - Burner Flame

PROPANE GAS: The input rate for LP units is factory set based on the oriﬁ ce size. Use the factory supplied kit to convert the boiler to LP. A combusiton analyzer must be used to ensure that the CO2 reading falls between 9% and 10.5% with a CO reading of less than 175 ppm air free.

CAUTION: Never increase the input to the boiler above that for which it is rated. Doing so can cause premature failure of the boiler!

Thermostat Adjustment

Set the heat anticipator to 1.1 amps when controlling the boiler directly. For zoned systems set the heat anticipator to match the amp draw of the zone valves or pump relays.

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 34

BOILER MAINTENANCE

The boiler should be cleaned and inspected once a year, before each heating season.

CAUTION: Servicing, inspection and adjustment must be done by a trained technician in accordance with all applicable local and national codes. Improper servicing or adjustment could damage the boiler!

Controls

Use a soft brush and/or a vacuum cleaner to ensure that the electrical components are free from dust or deposits that would impair the boiler’s performance.

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.

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 burner 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.

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!

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!

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 35

out

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.

WALL HUNG CONVERSION

This boiler is certiﬁ ed to be either mounted on the ﬂ oor as supplied, or mounted on a wall.

For wall mounting, perform the following steps.

1. Ensure that the desired location provides adequate room for the clearance, see Table 1, venting, and servicing.

2. Remove the right stainless steel panel, and discard.

3. You will see that underneath the panel, the boiler frame has mounting holes, designed for wall attachment.

4. The boiler must be mounted so the lag bolts enter the studs of the wall. If this is not possible use a 3/4" thick of plywood approximately 24 in, 610 mm, wide by 36 in, 914 mm, high.

5. Install two #14-3" lag bolts three quarters of the way into the surface, to the height you desire for mounting.

6. Lift the boiler onto the wall, and tighten the top lag bolts.

7. Once the unit is level, install the bottom two #14-3" lag bolts.

8. Remove the Air Inlet Pipe assembly and Metering elbow from the gas valve-venturi assembly, Figure

45.

Figure 45 - Air Inlet Pipe Removal

Figure 46 - Gas Valve Rotation

NEW LOCATIONS

FOR SCREWS

out

REMOVE SCREWS AND ROTATE 90° RE-INSTALL SCREWS IN NEW LOCATIONS

1/2 IN THREADED CONNECTION

10. Reattach the gas valve-venturi assembly to the side of the blower making sure the gasket is correctly orientated.

11. Re-install the Air Inlet Pipe assembly and Metering elbow from the gas valve-venturi assembly, in the vertical position, Figure 47.

Figure 47 - Air Inlet Pipe Installation

12. Install the gas line as per Figure 48 and follow the instructions in the GAS PIPING section of this manual.

9. Remove the two screws attaching the gas valveventuri assembly to the side of the blower and rotate the valve 90° so the 1/2" threaded connection is pointing down, Figure 46. Pay close attention to how the cork gasket is aligned.

Figure 48 - Gas Supply Piping

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 36

TROUBLE SHOOTING

This section is intended to assist the service technician in detecting and correcting common errors. The Sentry 2100 is equipped with an internal diagnostic system that veriﬁ es control operation. The following series of error codes has been developed to aid in diagnosing control problems:

Problem Detected Problem Solution

ER1 On Display

ER2 On Display

ER3 On Display

ER5 On Display

DHW Problem

The Safety High Limit of 215°F, 102°C, has been reached.

Water Probe... The water probe is transmitting an invalid signal - closed circuit.

Water probe...Sentry is sensing an open circuit at water probe. Or, the wiring to the outdoor probe is grounded.

The control has determined an Indirect water heater problem; the boiler has cycled off 10 times during a single call for domestic. The Indirect call will now be ignored until power is reset or the indirect call is interrupted.

1. Check to see if water is dripping on the sensor.

2. Reduce the Hi setting (and/or) ensure that there is proper water circulation in the system.

Check wiring

Check wiring. (Note: ER3 will be displayed if temperature sensed is less then 32°F, 0°C.) Note: If problem is corrected by resetting power, Sentry control had locked-up; contact Smith.

1. Not enough ﬂ ow to keep boiler from tripping on limit. Verify that a min. of 6 GPM, 0.4 L/s, ﬂ ow is going through boiler & indirect circuit.

2. Reduce indirect Aquastat setting, or Increase difference between (Lo Setting) and (indirect Aquastat setting).

3. Indirect limit or wiring failure.

ER6

Burner shuts off before set-point temperature is reached (and burner

light goes out)

“Flame Lock Out” Sentry has sensed a lack of 24V to the gas valve during operation or a Fenwal ignition lockout.

Reset calculation being used to lower HI setting.

Thermostat is satisﬁ ed

1. There is a problem in the ignition sequence; it could be caused by a faulty igniter, ﬂ ame sensor, gas valve or improper line pressure or combustion. Check ignition sequence to determine which component is not functioning.

(Sentry will retry ignition sequence 1 hour after ER6 code originally occurs or if control is reset)

2. Check for 24V between B on terminal block and F1 on Sentry plug, if not present a limit has tripped (see wiring diagram).

3. the Flow Switch on the GT-400 is also in the 24V circuit. Check for proper water ﬂ ow and ﬂ ow switch operation.

If OD probe is being used, the HI setting will be calculated using formula in Section 8.

1. If the thermostat demand light is turning off, the thermostat has satisﬁ ed.

2. If DHW temp light is turning off; the aquastat or call for domestic has been satisﬁ ed.

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 37

Problem Detected Problem Solution

ASO Indicates that the Air Switch is Open

ASC Indicates that the Air Switch is Closed

This is displayed when the boiler is expecting the air switch to be closed by a differential pressure generated when the combustion blower turns on. It can occur momentarily during normal operation. A problem is indicated when ASO is displayed continuously.

This is displayed when the boiler has turned the blower off and is expecting the air switch to be open. It can occur momentarily during normal operation. A problem is indicated when ASC is displayed continuously.

1. Are the vinyl tubes connected between the air switch and the ports on the inlet pipe. Negative side of switch connects to the port on the 1 1/2 in, 38 mm, ABS elbow.

2. Check for blockage on the intake and exhaust vents.

If fan is running, air switch may be faulty, ensure that it’s set for 0.2 in, 5.1 mm WC. The GT-400 condensate drain switch must be set at 3 in, 76 mm WC.

4. If fan is not running, check 120V wiring to blower, if ok remove low voltage harness from blower, if blower fails to start, replace blower, if blower does start problem may be with blower or Sentry control.

1. Is the fan running. If so check for 24V between C and D terminals, see wiring diagrams. If 24V is not present replace transformer.

2. Check venting termination with required venting described in manual.

Ignition Sequence not activated when burner light is on (Fan is on and Fenwal not ﬂ ashing)

Check for 24 Volts between terminal B1 on Sentry & Ground.

Check for 24 Volts between terminal F1 on Sentry & Ground.

Water Safety Limit trips (Automatic reset) Located in the supply manifold inside the boiler cabinet.

1. If there is 24V, indicates faulty wiring between BI and W1 on Fenwal, or faulty Fenwal.

2. If 24V is not present proceed to next step.

1. If 24V exists here but not at B1, indicates faulty relay inside Sentry, contact NTI, replace control.

2. If 24V is not present check for 24V at transformer.

3. If 24V exists at transformer, check wiring and safety limits. If 24V not present at transformer, check wiring and replace transformer if necessary.

May be caused by an error in the reading of the water temperature by the Sentry control. Watch cycle, and ensure the Sentry is displaying the correct water temperature and is modulating.

This device protects the boiler from overheating due to a lack of ﬂ ow passing through the unit when the burner is on.

FLOW MUST NEVER BE BLOCKED BY ANY VALVES INCLUDING MIXING OR ZONE VALVES.

Install unit as described in this manual.

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 38

Problem Detected Problem Solution

Ignition Sequence not activated when burner light is on (Fan is on and Fenwal not ﬂ ashing)

continued

Two Flashes on Fenwal

Three Flashes on Fenwal

Stack Safety Limit Trips (Automatic Reset) Located on the front of the ﬂ ue box.

The Fenwal controller thinks that there is a ﬂ ame prior to ignition.

Indicates Ignition Lockout.

This device protects the integrity of the plastic venting material. If the temperature of the ﬂ ue gases exceeds 225°F, 107°C, the limit will cut power to the control. Blocked internal tubes can increase the stack temperature to an unacceptable level. Flush out the boiler.

If the combustion sequence is normal, and there is no ﬂ ame prior to ignition, the Fenwal control is defective, and must be replaced.

If the condensate drain gets blocked, the boiler will become ﬂ ooded, and terminate operation, as the ﬂ ame rod becomes immersed. This will damage the ﬂ ame probe. To correct, free the drain blockage, and permanently prevent it from reoccurring. Remove and dry off the probe. Reinstall the probe and try for ignition, if it fails to ignite, leave the fan run for up to three hours to dry out the insulation and probe.

Boiler will not stay lit.

Boiler bangs or hisses

Indicates lack of a good ﬂ ame signal. In order to stay running the ﬂ ame signal must be at least 0.7 micro Amps.

Bangs or sounds like a kettle while burner is running indicating insufﬁ cient ﬂ ow.

Reset Boiler so it will attempt to ignite. Check for proper operation of ignition components. Make sure igniter glows and gas valve opens. Check for proper line pressure at gas valve when it opens. If boiler lights check for ﬂ ame signal between FC1 And FC2 on Fenwal control. If lower then 1.2 micro amps see Boiler will not stay lit below. Check combustion properties.

If the Burner light on the Sentry is going out, go to “Burner shutting off”. Check condensate drain for blockage and check the inlet piping for ingested snow or water (if the ﬂ ame rod gets wet, it may need to be replaced). Check for resistance from ﬂ ame rod to ground, must be an open circuit (O.L). Check for proper polarity of line and neutral wiring to the boiler.

Ensure the plumbing is as shown in manual. Check to see if pumps are faulty or end switches are stuck. This problem can lead to boiler overheating!

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 39

Problem Detected Problem Solution

Sentry Controller Locks-up

Display Goes Blank

Boiler Lights rough or pulsates

Excessive noise, current, or voltage spikes in the 120V power supply.

No power to control or control failure.

Typically an imbalance in the air to gas ratio.

Check for voltage at the wires going to the A-C-T terminals of the Boiler. Check the magnitude of the line voltage power supply. Check the Amp draw of output C1 and Ap (max 3 Amp). Check the Amp draw of control on start-up (max 6 Amps) Contact Smith.

Check for 120V between terminals L1 and L2 at Sentry. If 120V exists turn power off and remove line voltage harness from Sentry. Then check for resistance between L1 and L2 of control, if the circuit is open (O.L) the internal fuse has blown. Check for shorts in wires leading to circulators prior to replacing controller. If 120V not present, check wiring and for 120V at source.

Ensure that the venting lengths are in compliance with the venting sections above. Ensure that the line pressure during operation does not drop more than 20% from the static line pressure. Momentarily remove the intake vent from the boiler during ignition, if unit lights smoothly with intake vent disconnected reconnect and check for proper combustion if unit maintains smooth operation after ignition. Calibrate for proper combustion. If problem persists contact Smith.

Fan appears to be creating a noise in the housing

Slight vibration can cause noise in the residence. This is not a warranty issue.

Making a rubbing noise. This is not a

warranty issue.

Use ﬂ exible gas line to insolate the vibration noises between the gas valve and the line. Don’t hang gas lines from ﬂ oor joists. Use rubber insulators with gas line supports.

If gas valve is not held when the gas nipple is connected, the force of tightening the ﬁ tting can damage the valve, and warp the fan housing. If pipe is used, the gas line must not create any forces to the valve, either vertically (weight of line), or horizontally (misaligned connection)

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 40

The following are the thermister curves for diagnosing the water and outdoor air sensors.

1. Measure the resistance of the thermister when disconnected.

2. Using the appropriate chart, ﬁ nd the resistance and move vertically for the water probe or horizontally for the air probe until the line is intersected.

3. Move 90 degrees to the corresponding temperature.

4. If the temperature is plus or minus 10°F, - 12 °C, then the probe is operating correctly.

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 41

REPLACEMENT PARTS LIST

Replacement parts are available from your stocking wholesaler. Homeowners must contact their local installer or wholesaler.

Figure 48 - Replacement Parts Exploded View - Models GT150 and GT200

27A

11C

11B

11A

18A

SIOM-151

19A

19B

28A

Item Part Number Description

1 GT-82657 Premix burner, 135.8 – 150 Only 1 GT-82658 Premix burner, 200.6 – 200 Only 1A GT-82761 Premix Burner Gasket 2 GT-82457 Transformer, 24V 3 GT-82013 Sentry 2100 4 GT-82052 Blower #RG130 – 150 Only 4 GT-82661 Blower #RG148/1200 – 200 Only 5 GT-82054 Gas Valve (CVI) VK8115F1134B 5A GT-82065 Gas Valve 1/2" npt elbow 5B GT-82600 Gas Valve Vent connection 6 GT-82662 Air switch Huba @ .15"wc. 7 GT-82671 7 GT-83035

Thermister #T7335C2016 1 Mohm (150-200)

Thermister NTC 1/4" NPT, 1 Mohm (150ASME) 8 GT-82058 Ignition Moduel Fenwal #2465H 9 GT-82708 IGNITER, #601, c/w SS Heat shield 10 GT-82762 Rauscchert Flame Rod 11 GT-82763 Composit Flue Box 11A GT-82764 Composit Flue Box Gasket 11B GT-82765 Composit Flue Outlet Gasket 11C GT-83291-1 Flue Adapter Assembly 12 GT-82659 Manifold Limit, 1/8BSP, Brass (150-200) 12 GT-82992 Manifold Limit, 1/4NPT, Brass (150 ASME) 13 GT-82596 150 non-ASME Heat Exchanger 13 GT-83012 150 ASME Heat Exchanger 13 GT-82647 200 Heat Exchanger 14 GT-82650 LP oriﬁ ce 5.20mm – 150-200 Only 15 GT-82660 Stack Limit, 1/4BSP, SS, 190F, Dif=30 16 GT-82766 Blower gasket 150 Only

Item Part Number Description

16 GT-82719 Blower gasket 200 Only 17 GT-82622-1 Inlet Pipe assembly 18 GT-82127 Condensate nylon Y 18A GT-82913 Siphon Condensate Trap 19 GT-82767 Cast aluminum Burner door 19A GT-82769 Ceramic burner door disc 19B GT-82770 Burner door gasket 20 GT-82768 Igniter gasket 22 GT-82771 Extended air tube 27 GT-82754 Complete Control panel & Harness 27A GT-82754-1 PCB Optocoupler 28 GT-82054-1 CVI Venturi 01 – 150-200 Only 28A GT-82054-2 CVI Venturi Gasket 29 GT-82104-1 Air metering Elbow 30 GT-81027-1 Sentry 2100 (10k) Outdoor Air Sensor 31 GT-83223

1/8NPT Water Pressure Switch (after 5-1-06) 31 GT-83223-1 1/4NPT Water Pressure Switch (150 ASME) 32 GT-83112

Divider Plate Insulation c/w washer and screw A GT-82976-A Stainless steel Top B GT-82976-B Electrical box cover C GT-82976-C Stainless steel Left side D GT-82976-D Stainless steel Right side E GT-82976-E Stainless steel Front Door F GT-82976-F Galvanized Right Side G GT-82976-G Galvanized Bottom base H GT-82976-H Bottom Base support I GT-82976-I Galvanized Back

GT INSTALLATION AND OPERATION INSTRUCTIONSPage 42

REPLACEMENT PARTS LIST

Replacement parts are available from your stocking wholesaler. Homeowners must contact their local installer or wholesaler.

Figure 49 - Replacement Parts Exploded View - Model GT400

Reverse

Angle

14A

19A

19B 19

SIOM-152

Item Part Number Description

1 GT-83173 Premix Burner (For 400) 1A GT-82761 Premix Burner Gasket 2 GT-82457 Transformer, 24V 3 GT-83171 Sentry 2100 Assembly 4 GT-82994 EBM BLOWER #RG148/E 5 GT-82989 Gas Valve VR8615VB 1044B 5A GT-82991 Gas Valve Adapter, 3/4" NPT 5B GT-83194 Gas Valve Connector O-ring GT-83016 Gas Valve Harness 6 GT-82662 Air switch Huba @ 0.2"wc. 6C GT-82539 Air Vent 7 GT-83035 Thermister NTC 1/4" NPT, 1Mohm 8 GT-82058 Ignition Module (Fenwal) 9 GT-82708 IGNITER, #601, c/w SS Heat shield 10 GT-82762 Flame Rod Rauschert 11 GT-82906 Air Switch 604.E421180 set @ 3" wc 12 GT-82992 Limit Switch, 1/4"NPT, (Manifold) 13 GT-82926 400 Heat Exchanger, ASME 14 GT-82993 Gas Valve Oriﬁ ce, 8.0mm, NG 14A GT-83017 Gas Valve Oriﬁ ce, 6.2mm, LP 15 GT-81887 Flow Switch, FS-10C 16 GT-82766 Blower Gasket

17A

Item Part Number Description

17 GT-83037 TEE NYLON 3/4"HB to 3/4" 17A GT-83038 ADAPTER NYLON, 3/4" x 1/4" 18 GT-82913 SIPHON CONDENSATE TRAP 19A GT-82769 Burner Door Ceramic Disc 19B GT-82770 Burner Door Viton Gasket 20 GT-82768 Igniter Gasket 21 GT-83034 Exhaust Test Plug 22 GT-83195 Extended Air Tube 23 GT-83141 Control Panel, Complete 24 GT-82990 CVI Venturi 25 GT-83106 O-ring, Venturi to Blower 26 GT-83001 Test Port Retaining Clamp 27 GT-82754-1 PCB Optocoupler 28 29 GT-83170-1 Air Metering Assembly 30 GT-81027-1 Sentry 2100 (10K) Outdoor Probe 31 GT-83018 Vent Screen, 4" 32 GT-83019 Vent Screen, 6" 33 GT-83013 Nipple, 1-1/4" x 8", Brass 34 GT-83005 1-1/4"x 1-1/4"x 3/4" Tee Brass 35 GT-13701 RELIEF VALVE 3/4" #335 30 PSI 36 GT-82148 PRESSURE GAUGE 0-30 PSI 37 GT-83112 Divider Insul. (c/w washer & screw)

GT INSTALLATION AND OPERATION INSTRUCTIONS Page 43

WESTCAST, INC. 260 NORTH ELM STREET WESTFIELD, MA 01085 TEL. (413) 562-9631 FAX (413) 562-3799

Smith Cast Iron Boilers GT User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual