Smith Cast Iron Boilers GT User Manual

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

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Smith Cast Iron Boilers GT User Manual

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User Manual