Table of Contents
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This manual is intended only for use by a qualified heating installer/technician. Read and follow this manual, all supplements and related
instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these
instructions. Failure to do so can result in severe personal injury, death or substantial property damage.
Do not use the boiler during construction. Construction dust and particulate, particularly drywall dust, will cause contamination of
the burner, resulting in possible severe personal injury, death or substantial property damage. The boiler can only be operated with a dust-
free air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated by operation
with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.
Affix these instructions near to the boiler/water heater. Instruct the building owner to retain the instructions for future use by a qualified
service technician, and to follow all guidelines in the User's Information Manual.
GSX
Gas-fired residental steam
boilers
Models 88-288
Boiler manual
Installation and
operation instructions
GSXIOM-1
00-GSXIOM
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Table of Contents
Related Manuals for Smith 177
Summarization of Contents
Smith Boiler Installation and Operation Manual
Critical Safety Warnings for Installation
Essential warnings for installers and owners covering fire, explosion, severe injury, death, and property damage risks.
Manual Navigation and Safety Indicators
Understanding Manual Structure
Explains the manual's four main sections: Preinstallation, Installation, Start-Up, and Maintenance for clear guidance.
Interpreting Safety Alert Symbols
Defines DANGER, WARNING, CAUTION, and NOTICE symbols to communicate hazards and critical information effectively.
1. Preinstallation Requirements
General Preinstallation Checks and Warranty
Covers initial boiler inspection, proper storage, and the necessity of qualified installation for warranty validity.
Codes, Regulations, and Clearances
Details compliance with building codes, safety standards (ASME, ANSI, NFPA), and required clearances for safe installation and servicing.
E. Air for Combustion and Ventilation
Calculating Required Combustion Air Volume
Provides methods (Standard, Known Air Infiltration Rate) to determine minimum indoor air volume needed for appliance combustion.
Indoor Air Openings for Combustion Supply
Specifies requirements for sizing and locating indoor openings to ensure adequate combustion air supply to appliances.
4. Outdoor Combustion Air Methods
Two Permanent Outdoor Air Openings
Details the requirement for two openings for outdoor air supply, including minimum free area and specific placement criteria.
One Permanent Outdoor Air Opening
Outlines the requirements for a single opening for outdoor air supply, covering sizing, placement, and ducting options.
Combination and Mechanical Air Supply
Combination Indoor/Outdoor Air Supply
Describes supplementing indoor air with outdoor air openings when the available indoor volume is insufficient.
Mechanical Combustion Air Systems
Details requirements for mechanical air supply systems, including interlocks, air exchange rates, and replacement of exhaust air.
Combustion Air Ducts, Louvers, and Grills
Provides guidance on sizing, installation, material requirements, and termination points for combustion air ducts, louvers, and grills.
2. Boiler Placement and Venting
Packaged Boiler Handling and Inspection
Instructions for removing the boiler from its crate and pallet, emphasizing initial inspection for damage.
Chimney or Vent System Inspection and Code Compliance
Emphasizes inspecting the existing chimney/vent for condition, compliance with codes (NFGC), and proper draft for safe operation.
Automatic Vent Damper Installation Guidelines
Guidance on installing automatic vent dampers, stressing single-appliance use and required clearances for safety.
Vent Damper Mounting and Common Venting Removal
Vent Damper Mounting and Orientation
Details how to mount vent dampers directly to the draft hood or in the vent piping, including operator orientation.
Boiler Removal from Common Venting System
Procedures for safely removing a boiler from a common venting system, ensuring remaining appliances vent properly and safely.
4. Boiler Piping - Steam Systems
Steam Boiler Piping - Single Boilers
Instructions for installing steam supply pipes, including fittings, equalizing line, Hartford Loop, and specific pipe sizing recommendations.
Indirect Water Heater Piping
Steam Boiler Indirect Water Heater Piping
Details the installation of piping for indirect water heaters, including temperature limit control and circulator placement for optimal performance.
5. Fuel Piping Installation
Gas Pipe Installation and Sizing
Covers gas piping installation according to local codes and National Fuel Gas Code, including sizing based on input and pressure drop calculations.
5. Fuel Piping Operation and Safety
Gas Supply Pressure and Leak Testing
Ensures correct gas supply pressure, installation of service valve, sediment trap, and thorough leak testing for safety.
Gas Train Manifold and Ignition Protection
Illustrates a typical gas train manifold and details protection of ignition system components from water exposure.
6. Controls & Trim Installation
Steam Boiler Safety Valve Installation
Details the installation of the safety valve, including tapping locations, sizing, and discharge piping, with critical safety cautions.
7. Electrical Connections
Supply Wiring, Grounding, and Disconnects
Covers connecting supply wiring per codes, electrical bonding, and using a separate, permanently live supply line with a disconnect.
Control Wiring and Conduit Installation
Instructions for installing control wiring within approved electrical conduit, emphasizing correct placement of switches.
Wiring Diagram Index Reference
Provides a reference to specific wiring diagrams for different boiler models and ignition types, aiding in correct electrical hookup.
Wiring Diagrams for Standing Pilot Models
Connection and Ladder Diagrams Explained
Detailed diagrams showing electrical connections and ladder logic for boilers with probe low water cut-off and standing pilot ignition.
Wiring Diagrams for Spark Ignition Models
Spark Ignition Boiler Electrical Wiring
Illustrates connection and ladder diagrams for steam boilers featuring spark ignition and probe low water cut-off for accurate wiring.
Indirect Water Heater Wiring Diagram
Typical Indirect Water Heater Wiring Setup
Shows the wiring diagram for a typical steam boiler indirect water heater, including partner circulator and limit controls for proper function.
8. Boiler Operation Procedures
System Inspection and Boiler Filling
Procedures for inspecting the system, confirming utilities are off, and filling the boiler to the correct water level for operation.
Lighting Instructions and Pilot Check-Out
Guides on studying lighting instructions, performing pilot checks, and ensuring correct ignition sequences for safe startup.
Main Burner and Control System Checks
Main Burner System Performance Checks
Details checking gas pressure at main shut-off and manifold, and verifying burner input rate for optimal combustion.
Boiler Control Functionality Testing
Instructions for testing limit controls, low water cut-off, and main gas safety shut-off valves to ensure safety features are active.
Initial Boiler Cleaning (Boil-Out)
Outlines the process for initial boiler cleaning using washing soda to remove system impurities and prevent foaming.
Boiler Cleaning, Skimming, and Shutdown
Skimming Process and Boiler Draining
Describes the skimming procedure to remove contaminants and subsequent draining and refilling of the boiler system.
Safe Boiler Shutdown Procedures
Instructions for safely shutting down the boiler, including power and gas disconnection, and precautions for freezing temperatures.
Lighting Instructions: Standing Pilot Models
Safety Precautions Before Lighting Pilot
Crucial safety information and steps to take if gas is smelled before attempting to light the pilot, including emergency contacts.
Standing Pilot Lighting Procedure Steps
Step-by-step instructions for manually lighting the standing pilot, including safety checks and troubleshooting for ignition.
Lighting Instructions: Spark Ignition Models
Safety Precautions Before Spark Ignition Operation
Essential safety warnings and actions for gas detection before operating the spark ignition system, ensuring safe startup.
Spark Ignition Operation and Control Settings
Instructions for operating the spark ignition system, including setting thermostat and operating controls for proper function.
9. Routine Maintenance
Refractory Ceramic Fiber (RCF) Safety
Provides safety information and handling precautions for refractory ceramic fiber materials potentially present in the appliance.
General Boiler Maintenance Tasks
Covers disconnecting gas, insulating pipes, and addressing foreign matter or scale in boiler water for optimal performance.
Daily Boiler Operation Checks
Daily observations by the owner, including clearing combustibles, ensuring adequate ventilation, and checking for obstructions.
Monthly and Annual Maintenance
Monthly Maintenance Procedures
Includes checking floor drains, safety relief valve, low-water cut-off, limit controls, and vent damper operation for system integrity.
Annual Maintenance Procedures and Cleaning
Covers cleaning flueways/burners, inspecting venting, checking pilot/burner flames, and ensuring vent damper wiring.
10. Troubleshooting - Service Tips
Troubleshooting Pilot Outages
Lists common causes and suggested remedies for pilot outage issues, such as defective thermocouple, heavy draft, or no gas.
Main Gas Valve Won't Open Troubleshooting
Addresses issues with the main gas valve not opening for both spark ignited and standing pilot systems, citing causes like low water or power loss.
Burner Flame and Gas Spillage Troubleshooting
Yellow Flame and Gas Spillage Causes
Identifies causes for yellow flame (air adjustment, orifice size) and gas spillage from the draft hood relief opening, with remedies.
No Gas Flow and Start-Up Water Hammer
Troubleshooting for main gas valve opening without gas flow, and causes of water hammer upon initial start-up.
Water Hammer and Heat Distribution Issues
Water Hammer and Boiler Hammering Causes
Details causes and remedies for water hammer during mid-cycle and shut-down, and general hammering within the boiler.
Heat Distribution and Water Level Problems
Troubleshooting no heat, poor distribution, system overfilling, and excessive water level bounce due to various system issues.
11. Boiler Dimensions & Ratings
Boiler Tapping Locations and Functions
Diagram and table identifying the location, size, and function of various boiler tappings for connections.
Boiler Physical Dimensions and Ratings Table
Provides physical dimensions of the boilers and a table of boiler ratings, including heating capacity and AFUE for model selection.
Boiler Ratings and Specifications Overview
Detailed Boiler Model Ratings and AFUE
Table detailing Net I=B=R Ratings, Standing Pilot AFUE, Spark Ignition AFUE, water content, and shipping weight for various boiler models.
12. Repair Parts Identification
Comprehensive Repair Parts List
A comprehensive list of repair parts with item numbers, descriptions, and stock codes for easy ordering and replacement.
Repair Parts Visual Guide
Exploded View of Boiler Components
An exploded view diagram illustrating the location of various boiler components, cross-referenced with the repair parts list for identification.
Residential Cast Iron Boiler Limited Warranty
Warranty Coverage, Period, and Claims
Details the warranty coverage for cast iron boiler sections, the ten-year period, and the process for making warranty claims.
Warranty Exclusions and Limitations
Lists warranty exclusions such as auxiliary equipment, labor costs, and conditions like improper maintenance or installation damage.
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