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Smith Cast Iron Boilers GT Series Installation & Operation Manual

Gt series modulating, direct vent, gas-fired condensing boilers natural or propane 150,000 to 399,000 btuh input
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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.
Note: For LP gas use conversion kit: GT82650-1 on GT-150 & 200, GT83017-1 on GT-400
MODEL GT SERIES
Natural Or Propane
150,000 to 399,000 Btuh Input
WESTCAST, INC.
260 NORTH ELM STREET WESTFIELD, MA 01085
TEL. (413) 562-9631 FAX (413) 562-3799
gama
ENERGY STAR
ENERGY STAR
GTIOM-3

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  Summary of Contents for Smith Cast Iron Boilers GT Series

  • Page 1 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.
  • Page 2: Table Of Contents

    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,...
  • Page 3: Boiler Location

    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.
  • Page 4: Combustion Air

    Use appropriate adapters to increase the 1 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.
  • Page 5: Horizontal Direct Vent Systems

    fl ue box will be damaged voiding the warranty! 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,...
  • Page 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. •...
  • Page 7 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. Page 7...
  • Page 8 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...
  • Page 9: Vertical Direct Vent Systems

    Figure 13 - Wall Penetration Detail The debris screen provided with the boiler must be installed in the concentric terminal as shown in Figure Figure 14 - Debris Screen Installation VERTICAL DIRECT VENT SYSTEMS Read the information in the GENERAL VENTING GUIDELINES section before proceeding.
  • Page 10: Condensate Drain

    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...
  • Page 11: General Plumbing Guidelines

    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.
  • Page 12 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.
  • Page 13: Primary Loop Plumbing

    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...
  • Page 14 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.
  • Page 15 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 system piping.
  • Page 16 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.
  • Page 17 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 system piping.
  • Page 18: Gas Supply Piping

    Whenever the gas supply piping is pressure tested the boiler gas controls must be protected. If the test pressure is equal to, or less than 1/2 psi, 3.5 kPa, isolate the boiler by closing it’s manual shut off valve, see Figure 27. If the test pressure is greater than 1/2 psi, 3.5 kPa, disconnect...
  • Page 19: Electrical Wiring

    National Electrical Code, ANSI/ NFPA-70. Install a separate 120 volt 15 amp circuit for the boiler, Figures 28 and 29. A properly rated shut- off switch should be located at the boiler. The boiler must be grounded in accordance with the authority having jurisdiction, or if none, the latest revision of the National Electrical Code, ANSI/NFPA-70.
  • Page 20 Figure 29 - Basic Heating System and Indirect Tank Wiring Multiple 4 Wire Zone Valves Figure 30 shows the basic multiple zoned system uses normally closed four (4) wire zone valves. This wiring system is used with the piping shown in Figure 26. When there is a call for heat the room thermostat closes the circuit to the zone valve motor, thus opening the zone valve.
  • Page 21 GT INSTALLATION AND OPERATION INSTRUCTIONS Page 21 Figure 30 - Multiple 4 Wire Zone Valves...
  • Page 22 Page 22 GT INSTALLATION AND OPERATION INSTRUCTIONS Figure 31 - Multiple Zones w/ Taco Valve Controller, Models ZVC403 to ZVC 406...
  • Page 23 GT INSTALLATION AND OPERATION INSTRUCTIONS Multiple Zone Pump Controller Models Taco SR504, Argo ARM 861 Series Figure 32 shows the basic multiple zoned system using circulating pumps. This wiring system is used with the piping as shown in Figures 25. When there is a call for heat the room thermostat closes the circuit between the TT terminals on the pump controller.
  • Page 24 Page 24 GT INSTALLATION AND OPERATION INSTRUCTIONS Figure 33 - Boiler Ladder Diagram...
  • Page 25 GT INSTALLATION AND OPERATION INSTRUCTIONS Page 25 Figure 34 - Boiler Connection Diagram...
  • Page 26: Sentry 2100 Controller

    Misapplication of the controller will result in improper boiler operation. 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 27 RUN - Stores Values & initiates LO - Boiler Setpoint for DHW, 80 - 200°F, 27 - 93°C HI - Boiler Setpoint for Heating, 80 - 200°F, 27 - 93°C DIF - Differential, 1 - 40°F, -17°C - 4°C RES - Sets Outdoor Reset Curve Slope, 70°F, 21°C to HI...
  • Page 28 The vertical axis is the water temperature that the boiler will maintain and is also the Hi setting of the Sentry 2100T control. The Horizontal axis is the outdoor air temperature.
  • Page 29: Boiler Set Up

    Failure to take these precautions will prevent the boiler from operation properly. Fill the boiler and all of the radiation with water. Make sure that the system is completely purged of air, see GENERAL PLUMBING GUIDELINES.
  • Page 30 The gas supply pressure to the boiler while running at maximum rate must be between 4 to 9 in, 102 to 229 mm, W.C. for natural gas installations; 9 to 12 in, 229 to 305 mm, W.C. for propane installations. This pressure can be measured on the gas valve using a manometer, Figure 41 or 42.
  • Page 31 Open Open Closed Closed Prepurge Power to ignitor 120v from S1 Power to Gas valve Greater than 1.0 microA Boiler in standby Mode Thermostat End switch or relay closes T-C (Call for Heat) Awaiting Input Energizes Primary Pump (C1) Sentry 2100...
  • Page 32 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 with an ignition device which automatically lights the burner.
  • Page 33: Boiler Checking & Adjusting

    2. Call the gas company for the gas heating value. 3. Start the boiler and let it run for 15 minutes. 4. Using the gas meter and a stopwatch, clock the time that it takes to burn 10 cubic feet of gas and divide the time by 10.
  • Page 34: Boiler Maintenance

    BOILER MAINTENANCE The boiler should be cleaned and inspected once a year, before each heating season. CAUTION: Servicing, inspection and adjustment must be done by a trained technician in accordance with all applicable local and national codes. Improper servicing or adjustment could damage the boiler!
  • Page 35: Wall Hung Conversion

    220°F, 104°C. If the aquastat high limit fails to function properly replace it. WALL HUNG CONVERSION This boiler is certifi ed to be either mounted on the fl oor as supplied, or mounted on a wall. For wall mounting, perform the following steps.
  • Page 36: Trouble Shooting

    Note: If problem is corrected by resetting power, Sentry control had locked-up; contact Smith. 1. Not enough fl ow to keep boiler from tripping on limit. Verify that a min. of 6 GPM, 0.4 L/s, fl ow is going through boiler &...
  • Page 37 GT INSTALLATION AND OPERATION INSTRUCTIONS Problem This is displayed when the boiler is Indicates that the expecting the air switch to be closed by a Air Switch is Open differential pressure generated when the combustion blower turns on. It can occur momentarily during normal operation.
  • Page 38 Reset Boiler so it will attempt to ignite. Check for proper operation of ignition components. Make sure igniter glows and gas valve opens.
  • Page 39 20% from the static line pressure. Momentarily remove the intake vent from the boiler during ignition, if unit lights smoothly with intake vent disconnected reconnect and check for proper combustion if unit maintains smooth operation after ignition.
  • Page 40 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.
  • Page 41: Replacement Parts

    GT INSTALLATION AND OPERATION INSTRUCTIONS Replacement parts are available from your stocking wholesaler. Homeowners must contact their local installer or wholesaler. Figure 48 - Replacement Parts Exploded View - Models GT150 and GT200 SIOM-151 Item Part Number Description GT-82657 Premix burner, 135.8 – 150 Only GT-82658 Premix burner, 200.6 –...
  • Page 42: Replacement Parts List

    Page 42 GT INSTALLATION AND OPERATION INSTRUCTIONS Replacement parts are available from your stocking wholesaler. Homeowners must contact their local installer or wholesaler. Figure 49 - Replacement Parts Exploded View - Model GT400 SIOM-152 Item Part Number Description GT-83173 Premix Burner (For 400) GT-82761 Premix Burner Gasket GT-82457...
  • Page 43 GT INSTALLATION AND OPERATION INSTRUCTIONS Page 43...
  • Page 44 WESTCAST, INC. 260 NORTH ELM STREET WESTFIELD, MA 01085 TEL. (413) 562-9631 FAX (413) 562-3799...

This manual is also suitable for:

Gt-150Gt-200Gt-400Pgt-150Pgt-200Pgt-400