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Smith Cast Iron Boilers GB200 SERIES Installation, Operation And Maintenance Manual

Gas-fired steam cast iron boilers installation, operation & maintenance manual with replacement parts list.

 
INSTALLATION, OPERATION
& MAINTENANCE MANUAL
INTERMITTENT PILOT/VENT DAMPER
& STANDING PILOT/VENT DAMPER
SECTION 1: INTRODUCTION
Code Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Venting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Chimney Requirements . . . . . . . . . . . . . . . . . . . . . . . . . .3
Combustion Air Requirements . . . . . . . . . . . . . . . . . . . . .3
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Shipment of Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
SECTION 2: BOILER INSTALLATION
Step 1: Locating/Setting Boiler . . . . . . . . . . . . . . . . . . . . .4
Step 2: Installing Steam Piping . . . . . . . . . . . . . . . . . . . .5
Step 3: Installing Hydronic Components . . . . . . . . . . . . .5
Step 4: Venting Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Step 5: Installing/Testing Gas Piping . . . . . . . . . . . . . . . . .7
GB200 SERIES
WITH REPLACEMENT
PARTS LIST
GAS-FIRED STEAM
CAST IRON BOILERS
85,000 TO 165,000 BTUH INPUT
TABLE OF CONTENTS
WESTCAST, INC.
260 NORTH ELM STREET WESTFIELD, MA 01085
TEL. (413) 562-9631 FAX (413) 562-3799
www.smithboiler.com
Step 6: Wiring Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
SECTION 3: START-UP & OPERATION
Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . . .11
Prior To Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Start-Up & Adjustments . . . . . . . . . . . . . . . . . . . . . . . . .11
SECTION 4: MAINTENANCE
Before Each Heating Season . . . . . . . . . . . . . . . . . . . . .14
Steam Boiler Cleaning Instructions . . . . . . . . . . . . . . . . .15
How To Change Orifices . . . . . . . . . . . . . . . . . . . . . . . . .15
Heating System Problems & Causes . . . . . . . . . . . . . . .15
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . .16-17
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
GB200-IM-5
42-9184

Summary of Contents

  • Page 1

    Water Treatment ....... .3 Shipment of Boiler ......3 SECTION 2: BOILER INSTALLATION Step 1: Locating/Setting Boiler .

  • Page 2: Code Compliance, Venting Requirements

    At time of removal of existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while other...

  • Page 3: Chimney Requirements, Combustion Air Requirements, Water Treatment, Shipment Of Boiler

    Provisions for combustion air must be in accordance with the National Fuel Gas Code ANSI Z223.1 - latest edition, as well as all applicable local codes. If the boiler is installed in an unconfined space, adequate air will be available via normal infiltration.

  • Page 4: Step 1: Locating/setting Boiler

    SECTION 2: BOILER INSTALLATION STEP 1: LOCATING/SETTING BOILER Boiler may be installed in an alcove (see dimensions in Fig- ure 2.1). Locate boiler so connecting flue pipe between draft hood and chimney is as short as possible. Observe the following minimum clearances to combustibles: 18"...

  • Page 5: Step 2: Installing Steam Piping, Step 3: Installing Hydronic Components

    Supply outlet must run full size from the boiler to a header at least 24" above top of boiler. Condensate return piping should be connected to boiler through a "Hartford Loop."...

  • Page 6: Step 4: Venting Boiler

    Install flue pipe over top of vent damper and secure to damper housing with sheet metal screws or pop rivets. Attach vent damper cable to cable clamp on boiler left panel and join the Molex connector (see Figures 2.4 & 2.4A). FIGURE 2.4: VENT DAMPER INSTALLATION...

  • Page 7: Step 5: Installing/testing Gas Piping

    Install a full-sized sediment trap at the low point in gas line upstream of gas valve. Install a non-restrictive lubricated plug valve in the gas line close to the boiler. Install a ground joint union at the gas valve inlet to allow for servicing. Check local codes and utilities for any special requirements and proce- dures.

  • Page 8

    4331 Example: Boiler Model GB200-4H is to be installed. The distance from the existing gas meter to the installation site is 30 ft. What pipe size must be used? The local utility indicates the heating value of natural gas being supplied is 1000 Btu per cu.ft.

  • Page 9: Step 6: Wiring Boiler

    For vent damper-equipped models, connect thermostat to blue leads (see Figures 2.4 & 2.4A). NOTE: If any of original wire supplied with boiler must be replaced, use similar wire of 105° C rating. Other- wise, insulation may melt or degrade, exposing bare wire.

  • Page 10

    FIGURE 2.10: Wiring Diagram & Operation Sequence for Boilers Equipped with Intermittent Pilot, Vent Damper and 400 Series or M & M PS804 LWCO FIGURE 2.11: Wiring Diagram & Operation Sequence for Boilers Equipped with Standing Pilot, Vent Damper and 400 Series or M &...

  • Page 11: Sequence Of Operation, Prior To Start-up, Start-up & Adjustments

    This is a manu- al reset-type device and can be reactivated by depressing the spill switch reset button mounted on the left of the boiler’s draft diverter (see Figure 2.1 for switch location). The rollout switch prevents flame rollout from the boiler com-...

  • Page 12

    9. Start and stop burners several times by raising and low- ering the thermostat setting. 10. After boiler has been firing long enough to raise boiler pressure above minimum setting of the primary pressure- tol limit, check limit by turning its setting from maximum to minimum setting.

  • Page 13

    If you do not follow these instructions exactly, a fire or explosion may result with property damage, personal injury, or loss of life. A. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

  • Page 14: Before Each Heating Season

    In addition, the boiler should be examined by a quali- fied service professional at least once every year. DANGER:To avoid fire and explosion hazards: Do not...

  • Page 15: Steam Boiler Cleaning Instructions, How To Change Orifices, Heating System Problems & Causes

    4. Provide pipe connection (full size) from pressure relief valve opening to a convenient drain to serve as a vent. 5. Fill the boiler with a manual fill valve until water starts to trickle from this pipe. 6. Fire boiler at sufficient rate to generate and maintain steam.

  • Page 16: Replacement Parts, Replacement Parts

    GB200 Series REPLACEMENT PARTS LIST MODEL GB200 SERIES REPLACEMENT PARTS LIST NAME OF PART Jacket - Complete Jacket - Complete Jacket - Complete Burner - N.G./L.P. Burner w/Pilot Bracket - N.G./L.P. Base Door Ass'y Base Door Ass'y Base Door Ass'y...

  • Page 17

    NAME OF PART Standing Pilot Pilot Ass'y NG- Q314ALB, Q309A Pilot Ass'y NG- Q314ALB, Q309A Pilot Ass'y LP- Q314ALB, Q309A Pilot Ass'y LP- Q314ALB, Q309D — Thermocouple K16RA-30D Thermocouple K16RA-36D Gas Valve - NG VR8200H-1129 NG/LP* Transformer 115/24 V, 43VA Honeywell Intermittent Pilot System Pilot Ass'y NG- Q3451B Pilot Ass'y NG- Q3451B...

  • Page 18

    FIGURE 1: GB200 GENERAL ASSEMBLY...

  • Page 20: Warnings

    Carbon monoxide (CO) is a gas which is odorless, colorless and tasteless but is very toxic. If your Smith boiler is not working properly, or is not vented properly, dangerous levels of CO may accumulate. CO is lighter than air and thus may travel throughout the building. Brief exposure to high concentrations of CO, or prolonged exposure to lesser amounts of CO, may result in carbon monoxide poisoning.

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