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INSTALLATION, OPERATING
AND MAINTENANCE MANUAL
Modulating, Direct Vent, Gas-Fired Condensing Boilers
see note
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!
INSTALLER: THESE INSTRUCTIONS MUST BE AFFIXED ADJACENT TO THE BOILER.
CONSUMER: RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.
MODEL GT SERIES
Natural Or Propane
150,000 to 200,000 Btuh Input
Note: ASME on the GT-200 only
WESTCAST, INC.
260 NORTH ELM STREET WESTFIELD, MA 01085
TEL. (413) 562-9631 FAX (413) 562-3799
gama
ENERGY STAR
ENERGY STAR
GTIOM-2
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Table of Contents
Related Manuals for Smith GT-150
Summary of Contents for Smith GT-150
- Page 1 GTIOM-2 MODEL GT SERIES INSTALLATION, OPERATING AND MAINTENANCE MANUAL Modulating, Direct Vent, Gas-Fired Condensing Boilers Natural Or Propane 150,000 to 200,000 Btuh Input gama ENERGY STAR ENERGY STAR see note 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.
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Page 2: Table Of Contents
Boiler Ratings & Capacities ....... page 2 Boiler Location ........... page 3 Direct all questions to your Smith distributor or to the Clearances to Combustible Construction ..page 3 Customer Service Department, 260 North Elm Street, Combustion Air .......... -
Page 3: Boiler Location
7000 8000 9000 10000 Elevation (ft) GT-150 GT-200 WARNING: At elevations greater than 2000 ft, 2. An optimum site will be level, central to the hot water 660 m, the combustion of the GT must be checked piping system and close to an outside wall. -
Page 4: Combustion Air
Page 4 GT INSTALLATION AND OPERATION INSTRUCTIONS Table 1 - Clearances One of the following materials is to be used for the air intake pipe: Combustible Service • 3 in, 76 mm ABS. Clearance Clearance • 3 in, 76 mm PVC Sch.40 pipe. Surface •... -
Page 5: Horizontal Direct Vent Systems
The vent system Number System Length (see note) must be both gas tight and watertight. All horizontal GT-150 105 ft, 32 m vent piping must be sloped back to the boiler 1/4 in/ft, GT-200... - Page 6 Page 6 GT INSTALLATION AND OPERATION INSTRUCTIONS The vent terminal shall not terminate: Consult your weather office for the maximum typical • Directly above a paved sidewalk or a paved drive-way snowfall for your region. For example, in Boston MA the that is located between two buildings, and that serves maximum typical snowfall is 12 in, 305 mm.
- Page 7 GT INSTALLATION AND OPERATION INSTRUCTIONS Page 7 When penetrating an outside wall the air intake and vent For installations that have to exit the foundation below pipes must be constrained as shown in Figure 6. The grade excavate the site as shown in Figure 8 to a point openings through which the air intake and vent pipes below where the pipes exit the building.
- Page 8 Figure 12 - Vertical Concentric Terminal Location Concentric Air Intake and Vent Terminal 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.
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Page 9: Vertical Direct Vent Systems
GT INSTALLATION AND OPERATION INSTRUCTIONS Page 9 Figure 13 - Wall Penetration Detail 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. -
Page 10: Condensate Drain
25 mm, length of pipe into the opening to retain them, Figure 9. Concentric Air Intake and Vent Terminal 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. -
Page 11: General Plumbing Guidelines
GT INSTALLATION AND OPERATION INSTRUCTIONS Page 11 The following are important rules that must be followed CAUTION: The boiler fittings cannot support any when constructing the condensate system: weight. The plumbing system must be supported by 1. Connect the condensate trap to the drain using the building structure. -
Page 12: Primary Loop Plumbing
Page 12 GT INSTALLATION AND OPERATION INSTRUCTIONS Hot water boilers are designed to operate with airless PRIMARY LOOP PLUMBING water in the system. The GT boiler is provided with This low mass boiler requires a continuous minimum a 1/8 in, 3 mm, air vent located on the top of the unit. water fl... - Page 13 GT INSTALLATION AND OPERATION INSTRUCTIONS Page 13 Figure 23 - Primary Loop For Single Boiler Installations 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...
- Page 14 Page 14 GT INSTALLATION AND OPERATION INSTRUCTIONS Figure 24 - Primary Loop For Multiple Boiler Installations 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...
- Page 15 GT INSTALLATION AND OPERATION INSTRUCTIONS Page 15 Figure 25 - Secondary Loop For Multiple Zones Using Pumps Figure 26 - Secondary Loop For Multiple Zones Using A Bypass Valve Note: Velocity noise may be a problem when the entire output of the system pump is fl...
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Page 16: Gas Supply Piping
WARNING: Never use an open fl ame to test for at the installation site, call the nearest Smith distributor gas leaks. Always use an approved leak detection to resolve the problem. -
Page 17: Electrical Wiring
GT INSTALLATION AND OPERATION INSTRUCTIONS Page 17 ELECTRICAL WIRING 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 CAUTION: Label all wires prior to disconnection Sentry 2100 board. - Page 18 Page 18 GT INSTALLATION AND OPERATION INSTRUCTIONS Figure 29 - Basic Heating System and Indirect Tank Wiring Multiple Zones w/ Taco Valve Controller Multiple 4 Wire Zone Valves Figure 30 shows the basic multiple zoned system uses Models ZVC403 to ZVC 406 normally closed four (4) wire zone valves.
- Page 19 GT INSTALLATION AND OPERATION INSTRUCTIONS Page 19 Figure 30 - Multiple 4 Wire Zone Valves...
- Page 20 Page 20 GT INSTALLATION AND OPERATION INSTRUCTIONS Figure 31 - Multiple Zones w/ Taco Valve Controller, Models ZVC403 to ZVC 406...
- Page 21 GT INSTALLATION AND OPERATION INSTRUCTIONS Page 21 Multiple Zone Pump Controller Once the room thermostat is satisfi ed, it breaks power Models Taco SR504, Argo ARM 861 Series to the TT terminal of the pump controller de-energizing Figure 32 shows the basic multiple zoned system using the XX contacts.
- Page 22 Page 22 GT INSTALLATION AND OPERATION INSTRUCTIONS Figure 33 - Boiler Ladder Diagram...
- Page 23 GT INSTALLATION AND OPERATION INSTRUCTIONS Page 23 Figure 34 - Boiler Connection Diagram...
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Page 24: Sentry 2100 Controller
Page 24 GT INSTALLATION AND OPERATION INSTRUCTIONS Figure 37 - 2100T Display Screen SENTRY 2100T CONTROLLER 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 &... - Page 25 GT INSTALLATION AND OPERATION INSTRUCTIONS Page 25 Figure 38 - Input Conversion Chart Setting Sentry 2100T control Recommended Settings Programming is accomplished by a series of three push When programming the Sentry 2100T determine buttons located on the bottom side of the control. To what the hottest boiler temperature required for the enter the programming mode, press the function key coldest day will be.
- Page 26 Page 26 GT INSTALLATION AND OPERATION INSTRUCTIONS NOTE: The design temperature is 0°F, -18°C outside Determining Reset Temperature HI Calc Once the Sentry 2100T control identifi es the presence air, so at 0°F, -18°C or less, the hi setting is used, of a good outdoor sensor, the control will automatically and not surpassed.
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Page 27: Boiler Set Up
GT INSTALLATION AND OPERATION INSTRUCTIONS Page 27 Table 7 contains the range for the CO, CO2 and NOx that BOILER SET UP should be in a fl ue gas sample of a properly operating boiler at maximum input. NOTE: Before starting the boiler, turn off the electrical supply going to it. - Page 28 Page 28 GT INSTALLATION AND OPERATION INSTRUCTIONS C. Raise the thermostat at least 5 degrees above the D. With the burner in operation close the manual shutoff room temperature. The boiler should enter the pre- valve in the gas supply line. As soon as the burner purge mode before energizing the silicon carbide fl...
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Page 29: Operating Instructions
GT INSTALLATION AND OPERATION INSTRUCTIONS Page 29 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 •... -
Page 30: Boiler Checking & Adjusting
Page 30 GT INSTALLATION AND OPERATION INSTRUCTIONS BOILER CHECKING 3. For natural gas the CO reading should fall between 8% and 9.5% with a CO reading of less than 175 & ADJUSTMENT ppm air free. For LP gas the CO reading should fall Input Rate between 9% and 10.5% with a CO reading of less... - Page 31 GT INSTALLATION AND OPERATION INSTRUCTIONS Page 31 Heat Exchanger Cleaning 9. DO NOT install a damaged or badly corroded burner, Natural Gas - once every two years. replace it. Propane - once per year. 10. Inspect the ceramic burner disc for signs of damage or deterioration and replace it if necessary.
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Page 32: Wall Hung Conversion
Page 32 GT INSTALLATION AND OPERATION INSTRUCTIONS WALL HUNG CONVERSION 10. Reattach the gas valve-venturi assembly to the side of the blower making sure the gasket is correctly This boiler is certifi ed to be either mounted on the fl oor orientated. -
Page 33: Trouble Shooting
32°F, 0°C.) Note: If problem is corrected by resetting power, Sentry control had locked-up; contact Smith. ER5 On Display The control has determined an Indirect 1. Not enough fl ow to keep boiler from DHW Problem water heater problem;... - Page 34 Page 34 GT INSTALLATION AND OPERATION INSTRUCTIONS Problem Detected Problem Solution This is displayed when the boiler is 1. Are the vinyl tubes connected between Indicates that the expecting the air switch to be closed by a the air switch and the ports on the inlet Air Switch is Open differential pressure generated when the pipe.
- Page 35 GT INSTALLATION AND OPERATION INSTRUCTIONS Page 35 Problem Detected Problem Solution Ignition Sequence Stack Safety Limit Trips (Automatic Reset) This device protects the integrity of the not activated when Located on the front of the fl ue box. plastic venting material. burner light is on If the temperature of the fl...
- Page 36 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. No power to control or control failure. Check for 120V between terminals L1 and Display Goes Blank L2 at Sentry.
- Page 37 GT INSTALLATION AND OPERATION INSTRUCTIONS Page 37 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.
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Page 38: Replacement Parts
Page 38 GT INSTALLATION AND OPERATION INSTRUCTIONS Figure 48 - Replacement Parts Exploded View SIOM-36... -
Page 39: Replacement Parts List
GT INSTALLATION AND OPERATION INSTRUCTIONS Page 39 REPLACEMENT PARTS LIST Replacement parts are available from your stocking wholesaler. Homeowners must contact their local installer or wholesaler. Item Description Part Number GX-150 GX-200 Premix Burner GT-82657 Premix Burner GT-82658 Premix Burner Gasket GT-82761 Extended Air Tube GT-82771... - Page 40 WESTCAST, INC. 260 NORTH ELM STREET WESTFIELD, MA 01085 TEL. (413) 562-9631 FAX (413) 562-3799...