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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.
NOTE: 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 28HE
INSTRUCTIONS
TO INSTALLER
WESTCAST, INC.
260 NORTH ELM STREET WESTFIELD, MA 01085
TEL. (413) 562-9631 FAX (413) 562-3799
28HE-IOM-1
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Table of Contents
Related Manuals for Smith Cast Iron Boilers 28HE
Summary of Contents for Smith Cast Iron Boilers 28HE
- Page 1 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 28HE TO INSTALLER WESTCAST, INC. 260 NORTH ELM STREET WESTFIELD, MA 01085 TEL.
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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 28HE low pressure steam or hot water boiler. The 28HE 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
Figure 1 -Service Clearances to Adjacent Construction WARNING: Never install a 28HE 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 and combustible construction. -
Page 4: Chimney & Vent Pipe Connections
SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 4 All Air From Inside The Buidling 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 Note: These sizes are based on a 20 foot chimney height. Figure 2- Vertical Venting The 28HE is designed for pressurized operation with a back pressure of 0.10 in, 2.54 mm W.C. before the smoke hood slide damper. If the vent configuration results in a back pressure greater than this, the burner capacity may have to be verified.
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Page 6: Common Vent Systems
SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 6 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
BOILER ASSEMBLY Locate the boiler installation site based on the guide- lines set forth in the BOILER LOCATION section. WARNING: Never install a 28HE boiler on top of comustible flooring without consulting the local building authorities for proper installation guidelines! Failure to comply with this warning... - Page 8 SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 8 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 28HE 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 Heat Transfer Rod Installation, Figure 7 The high efficiency 28HE comes with design certified heat transfer rod sets. Each tube of 15 heat transfer rods will baffle one flue. In order to obtain the high efficiency for which the boiler was designed, the heat transfer rods must be properly installed, Figure 7.
- Page 11 SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 9 - Burner Mounting Plate Details Observation Port Assembly, Figure 10 1. Position the hinged end of the steel flapper door, item 5, over the boss on the observation port cover, item 4.
- Page 12 SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 12 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 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 12. Figure 12 - Tankless Heater Installation 3.
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Page 14: General Piping Requirements
SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 14 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
Water Column Piping A variety of water level controls are available for the 28HE. The water column piping needed to properly mount each control is available from Smith. Figure 18 shows a typical water column piping arrangement. The 1"... - Page 16 SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 16 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 21.
- Page 17 SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 17 Figure 19 - Typical Single Water Boiler Piping Figure 20 - Typical Multiple Water Boiler Piping...
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Page 18: Steam Boiler Piping
SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 18 Figure 21 - 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 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS Table 9 - Steam Boiler Capacities I=B=R Gross Output Boiler Model 28HE-S-4 28HE-S-5 1166 28HE-S-6 1433 28HE-S-7 1699 28HE-S-8 1965 28HE-S-9 2232 28HE-S-10 2498 28HE-S-11 2764 28HE-S-12 3031 28HE-S-13 3297 28HE-S-14 3563 1044...
- Page 20 SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 20 Figure 23 - Typical Steam Piping - Gravity Return for Multiple Boilers Figure 24 - Typical Steam Piping - Pumped Return for Multiple Boilers...
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Page 21: Burner Installation
SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS Install 3" nipples into the two 3" NPT tappings in the front section and install ball valves so the boiler can be blown down. The feed water requirements for steam boilers at full input are shown in Table 9. -
Page 22: Electrical Wiring
SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 22 WARNING: Never use an open flame to test for gas leaks. Always use an approved leak detection method. Failure to comply with this warning can cause extensive property damage, severe personal injury or death! Whenever the gas supply piping is pressure tested the boiler gas controls must be protected. -
Page 23: Boiler Checking & Adjustment
CAUTION: If the flue gas temperature exiting the smoke hood is less than 320 F, 160 C at full rated input, the number of heat transfer rods in the boiler must be reduced. Failure to protect the boiler from low flue gas temperatures will shorten the life of the boiler and breeching and void the warranty! Flue Temperature Adjustment 1. -
Page 24: Boiler Maintenance
SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 24 BOILER MAINTENANCE WARNING: Servicing, inspection and adjustment of the boiler must be done by a trained technician in accordance with all applicable local and national codes. Improper servicing or adjustment can result in property damage,... -
Page 25: Repair Parts
SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 25 Figure 26 - Boiler Assembly... - Page 26 SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 26 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 Heat Transfer Rod Set...
- Page 27 Ref # Name of Part Observation Glass Cover Plate 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" Burner Mounting Plate Hardware Burner Mounting Plate Insulating Block Burner Mounting Plate Rope Seal, 3/8 x 7 ft.
- Page 28 Any appliance that burns natural gas, propane gas, fuel oil, wood or coal is capable of producing carbon monoxide (CO). 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.