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MEA#273-89-E
GAS OR OIL BOILER
INSTALLATION & OPERATING
DESIGNED AND TESTED ACCORDING TO A.S.M.E. BOILER AND PRESSURE
VESSEL CODE, SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE
OF: 15 PSI STEAM OR 80 PSI WATER.
READ THESE INSTRUCTIONS CAREFULLY. THEY WILL
SAVE YOU VALUABLE TIME WHEN ASSEMBLING THE BOILER.
WARNING: If the information in this manual is not followed exactly, a fire or explosion
may result causing property damage, personal injury or loss of life.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch. Do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER.
CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.
FOR JACKET ASSEMBLY AND BURNER SET UP SEE SEPARATE INSTRUCTIONS.
In Canada: 5211 Creekbank Road, Mississauga, Ont. L4W 1R3 (905) 625-2991 Fax (905) 625-6610
SERIES 28A
INSTRUCTIONS
TO INSTALLER
WESTCAST, INC.
260 NORTH ELM STREET WESTFIELD, MA 01085
TEL. (413) 562-9631 FAX (413) 562-3799
28A-IOM-7
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Table of Contents
Related Manuals for Smith Cast Iron Boilers Series 28A
Summary of Contents for Smith Cast Iron Boilers Series 28A
- Page 1 Installation and service must be performed by a qualified installer, service agency or the gas supplier. INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER. CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES. FOR JACKET ASSEMBLY AND BURNER SET UP SEE SEPARATE INSTRUCTIONS.
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Page 2: Table Of Contents
Health Warnings ... back cover BEFORE YOU START This manual covers the assembly, installation, operation and maintenance of a Series 28A low pressure steam or hot water boiler. The 28A Series boilers are supplied completely knocked down for field assembly, knocked down but with an assembled block or as complete factory assembled packaged boilers. -
Page 3: Combustion Air & Ventilation
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 1- Service Clearances to Adjacent Construction WARNING: Never install a 28A boiler on top of combustible flooring without consulting the local building authorities for proper installation guidelines! A minimum clearance of 6 in, 0.15 m must be maintained between the boiler... -
Page 4: Chimney & Vent Pipe Connections
Page 4 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS All Air From Inside The Building If the boiler is to be located in a confined space mini- mum clearances of 24 in, 610 mm must be maintained between the boiler and any adjacent construction. When installed in a confined space, two permanent openings communicating with an additional room(s) are required. - Page 5 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Chimney Inspection & Sizing If this boiler will be connected to a masonry chimney, a thorough inspection of the chimney must be performed. Ensure that the chimney is clean, properly constructed, lined and properly sized, see Figure 2. Table 2 lists the equivalent breeching and flue sizes required for the 28A boilers.
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Page 6: Common Vent Systems
Page 6 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS VENT CONNECTIONS WARNING: Never modify or alter any part of the boiler’s smoke hood. This includes the removal or alteration of any baffles. Never install a vent pipe of a diameter different than that of the boiler smoke hood outlet. -
Page 7: Boiler Assembly
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS c) Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. - Page 8 Page 8 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Completed boilers must be tested as follows: Steam Boilers – the assembled boiler sections shall be subjected to a hydrostatic test pressure of not less than 45 psig, 315 kPa .
- Page 9 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS 5. Insert the large port connector with its steel inner ring into the upper port. 6. Insert the two round port connectors into the lower ports. NOTE: Apply the spray adhesive supplied with the boiler to the port recess to hold the port connector in place if necessary.
- Page 10 Page 10 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS 9. Assemble the rest of the sections following steps 3 through 8 above. 10. Hydrostatically test the boiler by following the instructions on page 8. 11. While the boiler is being filled confirm that all of the draw rods are properly torqued and that there are no leaks.
- Page 11 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 8 - Burner Mounting Plate Details Observation Port Assembly, Figure 9 1. Position the hinged end of the steel flapper door, # 5, over the boss on the observation port cover, # 4.
- Page 12 Page 12 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Observation Port Installation 1. Screw the four 5/16-18 x 1 1/2 studs into the tapped holes around the observation cover opening in the back section. 2. Place the observation port cover assembly over the studs and install the washers and nuts.
- Page 13 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Tankless Heater Installation - Optional 1. Clean the heater flange to remove any rust or debris. 2. Install the four 7/16" x 1 1/2" studs into the tapped holes in the tankless heater flange on the section, Figure 11.
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Page 14: General Piping Requirements
Page 14 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS GENERAL PIPING REQUIREMENTS CAUTION: Never use automotive antifreeze in the boiler or heating system. If antifreeze is necessary it must be formulated specifically for hydronic heating systems, such as ethylene or propylene glycol. -
Page 15: Water Boiler Piping
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 15 - Relief & Safely Valve Piping WATER BOILER PIPING The supply and return connections should be sized to suit the system, see Figures 13, 14, 16, 17 and Tables 5 & 6. Do not pipe the supply from the bottom port or the return to the top port, the boiler will not work properly. - Page 16 Page 16 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Piping For Use With Cooling Units The boiler, when used in connection with a refrigeration system, must be installed so the chilled medium is piped in parallel with the boiler. Appropriate valves must be used to prevent the chilled water from entering the boiler, see Figure 20.
- Page 17 Page 17 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 18 - Typical Single Water Boiler Piping Figure 19 - Typical Multiple Water Boiler Piping...
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Page 18: Steam Boiler Piping
Page 18 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 20 - Chilled Medium Diagram NOTE FOR HEATING: VALVES “H” OPEN, VALVES “C” CLOSED. FOR COOLING: VALVES “H” CLOSED, VALVES “C” OPEN. EXP. TANK VENT RELIEF VALVE PUMP FILL VALVE... - Page 19 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Table 9 - Steam Boiler Capacities I=B=R Gross Output Boiler Model 28A-S-4 28A-S-5 1166 28A-S-6 1433 28A-S-7 1699 28A-S-8 1965 28A-S-9 2232 28A-S-10 2498 28A-S-11 2764 28A-S-12 3031 28A-S-13 3297 28A-S-14 3563 1044...
- Page 20 Page 20 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 22 - Typical Steam Piping - Gravity Return for Multiple Boilers Figure 23 - Typical Steam Piping - Pumped Return for Multiple Boilers...
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Page 21: Burner Installation
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Install 3" nipples and ball valves in the two 3" NPT front section tappings so the boiler can be blown down. The feed water requirements for steam boilers at full input are shown in Table 9. The addition of water to the boiler should be controlled by sensing the actual boiler water level. -
Page 22: Electrical Wiring
CAUTION: The supply temperature of a boiler set for a 20 F, 11 C temperature rise must not be below 140 F, 60 C for an oil boiler, 149 F, 65 C for a gas boiler. Failure to protect the boiler from low return... -
Page 23: Boiler Checking & Adjustment
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS BOILER CHECKING & ADJUSTMENT CAUTION: Never increase the input to the boiler above that for which it is rated. Doing so can cause premature failure of the boiler! Low Water Cutoff Ensure that the low water cutoff device(s) function(s) properly. - Page 24 Page 24 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS 6. Vacuum out the burner base and clean and inspect all of the components. Replace any damaged or badly corroded parts. 7. Inspect the cleanout cover insulation and rope seal. If damaged or deteriorated replace them.
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Page 25: Repair Parts
Page 25 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 25 - Boiler Assembly... - Page 26 Page 26 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Ref # Name of Part Front Section Graphite Port Connector Set Draw Rod Washers 5/8" x 11" Draw Rods Draw Rod Hex Nuts Rope, 1/2" x 12 1/2 feet Cleanout Cover Assembly...
- Page 27 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Ref # Name of Part Rear Observation Port Hardware Burner Mounting Plate Assembly, 9" Burner Mounting Plate Assembly, 10 1/4" Burner Mounting Plate Assembly, 12 1/2" Burner Mounting Plate Assembly, 10 1/4" Burner Mounting Plate Assembly, 7 3/4"...
- Page 28 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.