Smith Cast Iron Boilers GVIOM-5R User's Manual
Contents
1. A INDUCER PS Foa pu J x x CONTROL 2 30 r r 1 Lt 3 3 A E i GAS INLET 1 oy JUNCTION BOX ie ROLL OUT CONTROL CENTER eWITCH 045 1 4 i amp INDUCER RELAY 4 Qe pm GAS VALVE Y H 5 5 8 2 4 13 1 2 a 11 1 2 gt 27 5 8 A FRONT VIEW SIDE VIEW Notes 1 Components located behind front panel 2 Vertical dimensions must be adjusted when using a base pan or concrete foundation under the boiler TABLE 1 Boiler Dimensions Boiler Size Dimension Dimension Vent Dia Vent Dia Sections A B CATEGORY CATEGORY Single Wall Galv Horizontal Vent in mm in mm in mm in mm 3 10 2 6 27 6 62 4 102 4 102 4 1398 346 313 16 97 4 102 4 102 5 16 416 53 6 132 4 102 4 102 6 19 486 6946 167 5 127 4 102 7 21 556 715 16 202 5 127 4 102 Page 6 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS FIG NO 3 Special Base Installation 77777772. A HOT u T N Lo POWER SUPPLY CIRCULATOR ZONE 1 VOLTAGE CIRCULATOR THERMOSTAT POWER 1 SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED R8285A POWERS 3 V8043 ZONE VALVES OR ONLY 2 V8043 S IF AMBIENT TEMPERATURE EXCEEDS 77F USE AND ADDITIONAL TRANSFORMER FOR EVERY ADDITIONAL 3 OR LESS VALVES FIG NO 17 Multi Zone Diagram LINE VOLTAGE 22 LOW VOLTAGE R8285D ZONE 1 THERMOSTAT ZONE 2 THERMOSTAT ZONE 3 THERMOSTAT 1 R8230B CIRCULATOR ZONE 1 R8230B CIRCULATOR 6 ZONE 2 e R8230B CIRCULATOR ZONE 3 L1 POWER SUPPLY N PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED AS MANY AS FOUR R8230B RELAYS MAY BE POWERED BY THE R8285A ADDITIONAL GROUPS OF 4 REQUIRE AN ADDITIONAL TRANSFORMER Page 16 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS FOR Your SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance is equipped with an ignition device that automatically lights the burner follow operating instructions do not try to light the burner by hand B Before operating smell all around
3. OUTSIDE WALL 18 MIN VENT SYSTEM Ball BOILER The maximum vent length for 3 diameter vent systems is 20 feet one 90 elbow and a vent terminal or 15 feet two 90 elbows and a vent terminal The maximum vent length of 4 diameter vent systems is 30 feet four 90 elbows and a vent terminal To maximize the performance of the vent system locate 90 elbows as far from the boiler and one another as possible The minimum horizontal vent length is 4 feet see FIG NO 4B The vent system must be pitched down toward the vent terminal 1 4 per foot If any part of a single wall metal vent system passes through an unheated space it must be insulated with insulation rated for 450 F WARNING The bottom of the vent terminal must be located at least 12 inches above grade including the maximum snow line Failure to provide adequate vent terminal clearance for this boiler can result in excessive levels of carbon monoxide that can result in severe personal injury or death Horizontal vent systems shall terminate at least 4 ft 1 3 m below 4 ft 1 3 m horizontally from or 1 ft 0 23 m above any door window or gravity air inlet into any building It must not terminate less than 4 ft 7 3 m horizontally from and in no case above or below unless a 4 ft 1 3 m horizontal distance is maintained from electric meters gas meters regulators and
4. NO 8 The dedicated bypass circulator provides a strong blending flow without diminishing the flow available to any heating zone Any residentially sized circulator is adequate for this purpose Each of these bypass solutions also has the added benefit of increasing circulation in the boiler which will maximize tankless coil output and increase the accuracy of temperature sensing controls FIG NO 8 RETURN PUMPED BYPASS Reverse Acting Aquastats An alternative for existing systems experiencing condensation that does not require re piping the boiler utilizes a reverse acting aquastat one that makes on temperature rise This approach works best in single zone systems Wired in series with the circulator this control holds the circulator off until the boiler reaches an acceptable temperature and then starts system circulation see FIG NO 9 The most commonly available reverse acting aquastat is a Honeywell L4006B The aquastat should be mounted in an immersion well directly installed in the boiler The use of heat conductive grease Honeywell part 972545 in the immersion well is strongly recommended for fast and accurate temperature response Set this adjustable aquastat to make at no less than 130 F 54 C While this method can cause the circulator to cycle more frequently setting the aquastat s differential to the maximum 25 30 F will minimize short cycling FIG 9 115 volts re
5. 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 CAUTION Do not install this boiler in a location subject to negative pressures or improper operation will occur 5 Do not place this boiler in a location that would restrict the introduction of combustion air into the boiler NEVER store objects on or around the boiler WARNING Never store combustible materials gasoline or any product containing flammable vapors or liquids in the vicinity of the boiler Failure to comply with this warning can result in extensive property damage severe personal injury or death 6 Ifthe boiler is to be located in an alcove closet or other confined space the distances from the boiler and it s vent system to all combustible construction must be equal to or greater than the minimum clearances in Figure 1 When installed in a closet or confined space two permanent openings of equal area adjoining another room or rooms having sufficient volume to meet the requirements of an unconfined space must be provided Each opening must have a minimum free area of one square inch 1000 Btu hr 2200 mm kW based on the total input rating of all gas utilization equipment in the confined area Each opening must be no less than 100 in 64516 in size The upper opening must be within 12 in 305 mm of but not less than 3 in 76
6. Junction Box 55526 T T T Page 23 o O O 14 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 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 Exposure can be fatal and exposure to high concentrations may result in the sudden onset of symptoms including unconscious ness Symptoms of CO poisoning include dizziness vision problems shortness of breath headaches loss of muscle control unclear thinking nausea weakness unconsciousness The symptoms of CO poisoning are often confused with those of influenza and the highest incidence of poisoning occurs at the onset of cold weather or during flu season A victim may not experience any symptoms only one symptom or a few symptoms Suspect the presence of carbon monoxide if symptoms tend to disappear when you leave your home The following signs may indicate the presence of carbon monoxide Hot gases from appliance venting system pipes or chimney escaping into the living space e Flames coming out around the appliance e Y
7. Pressure Vessel Code Section IV see FIG NO 5 Ensure that the boiler is level from front to back and from side to side Use metal shims to level the boiler Never use combustible materials for shims CAUTION To prevent damage due to excessive conden sation one of the following piping options should be used Page 10 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS FIG NO 5 Heating System Piping DISCHARGE PIPE SIZE TO EQUAL VALVE OUTLET DO NOT RESTRICT FLOW CX VERON 4444 2 4 A 4 2 4 A 4 344 1 4 SUPPORT DISCHARGE PIPING SO AS TO AVOID STRAIN ON THE VALVE BODY FOR DISCHARGE THROUGH ROOF CONSULT THE SMITH CO 1 CLEARANCE MUST BE MAINTAINED BETWEEN HOT WATER PIPING AND COMBUSTIBLE CONSTRUCTION DISCHARGE SO AS TO AVOID EXPOSURE OF PERSONS TO HOT LIQUID OR VAPOR LEAVE OPEN END VISIBLE FOR PERIODIC INSPECTION FOR SLOW LEAKAGE OR DRIPS System Bypass For systems using a circulator on the return as either a single zone or multiple zones with zone valves install a system bypass line between the supply and return on the suction side of the circulator see FIG NO 6 Install a metering valve in this bypass line to regulate the amount of flow that will be diverted to the return A plug valve offers the best control for this application Although other valves may be less expensive a plug valve wi
8. chimney must have a vitreous tile lining that is clean properly constructed and properly sized e the chimney must not be located on an external wall or be located in an unheated space unless the chimney is lined with a corrosion resistant metal liner and a condensate trap is installed e the boiler must not be connected to a flue used for a fireplace wood stove or other solid fuel device If possible the boiler and a gas fired hot water heater should be connected to the same chimney flue They must have their own vent connector and enter the flue at least 6 in 152 mm apart Consult the latest revision of the National Fuel Gas Code ANSI Z223 1 and follow all local codes to ensure that the chimney is the proper size for the given installation WARNING Failure to connect this boiler to the chimney using vent pipe of the proper diameter as listed in Table 1 could cause carbon monoxide poisoning leading to death Page 8 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS Vent Connections to Chimneys Use Type B1 or single wall metal vent pipe from the boiler to the chimney If used a 4 in to 5 in 102 mm to 127 mm increaser must be fastened directly to the boiler vent collar with sheet metal screws no longer than 1 2 in 13 mm Use the shortest straightest vent system possible for the particular application The vent system should be sloped up toward the chimney 1 4 in ft 2 cm m Ensure that the flue pipe is properly
9. mm from the top of the enclosure The bottom opening must be within 12 in 305 mm of but not less than 3 in 76 mm from the bottom of the enclosure WARNING Never install a PGV100W propane boiler in a closet or other confined or enclosed space Failure to comply with this warning could result in a fire or explosion causing extensive property damage severe personal injury or death Page 4 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS COMBUSTIBLE FLOOR OPTION The GV100W boiler has been designed for use on non combustible floors only If a GV100W boiler is to be installed on combustible flooring of any type it MUST be installed using the special base designed by the Smith Cast Iron Boiler Co Never use a substitute base when installing this boiler on a combustible floor WARNING Never install a GV100W boiler on combustible flooring without using the special base specifically designed for it by the Smith Cast Iron Boiler Co Do not alter in any way the special base supplied by the Smith Cast Iron Boiler Co Failure to comply with this warning may result in a fire causing extensive property damage severe personal injury or death To order the special base contact the nearest Smith Cast Iron Boiler distributor and ask for Smith s Special Base Part No CB100 sections The number of sections is part of the model number recorded on the rating plate If the model number is GV100W 7 the 7 specifies
10. prevent inhalation of airborne fibers Crystalline silica fibers have been identified as carcinogenic or possibly carcinogenic when inhaled CAUTION Servicing inspection and adjustment must be done by a trained technician in accordance with all applicable local and national codes Verify proper operation after servicing Improper servicing or adjustment can damage the boiler The boiler should be cleaned and inspected once a year before each heating season Use a soft brush and or a vacuum cleaner to ensure that the burners and ignition components are free from dust soot dirt corrosion or other deposits that would impair the boiler s performance Refer to page 22 for component identification Burner Removal 1 Close the manual shutoff valve in the gas supply line and turn off electrical power to the boiler 2 Remove the front access panel 3 Disconnect the gas supply see FIG NO 8 4 Where applicable disconnect the wires and pilot tube from the gas valve 5 Remove the two nuts holding the manifold assembly and remove the assembly 6 Remove the top half of the burner support panel and the burners Burner Installation 1 Donotinstall damaged or badly corroded burners replace them 2 Insert the crimped end of each burner into the slot in the burner base rear panel 3 Work the manifold assembly into position and start the two retaining nuts Slide the top half of the burner support panel in place and tight
11. 7777771 FRONT GRILL SPECIAL BASE COMBUSTION AIR WARNING This boiler must be supplied with combustion air in accordance with Section 5 3 Air for Combustion amp Ventilation of the latest edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and all applicable local building codes Failure to provide adequate combustion air for this appliance can result in excessive levels of carbon monoxide which can result in severe personal injury or death To operate properly and safely this boiler requires a continuous supply of air for combustion Oxygen is used by the burners in the boiler to burn the gas An adequate supply of outside air must be available to replace the air used by this process Older houses often have enough leakage to provide an adequate amount of combustion air provided that the demand for combustion air is not too great Homes that are relatively new or tight will most likely require the installation of a fresh air duct or other means of providing air for combustion Any home utilizing other gas burning appliances a fireplace wood stove or any type of exhaust fan must be checked for adequate combustion air when all of these devices are in operation at one time Sizing of an outside air duct must be done to meet the requirements of all such devices see Table 2 TABLE 2 Combustion Air Duct Sizing Fresh Air 14 Wire Metal Wooden Duct Size Mesh Screen Louvers
12. ESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES WESTCAST INC Gmit 260 NORTH ELM STREET WESTFIELD MA 01085 CAST IRON BOILERS TEL 413 562 9631 FAX 413 562 3799 In Canada 5211 Creekbank Road Mississauga Ont LAW 1R3 905 625 2991 Fax 905 625 6610 Page 2 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS AVERTISSMENT Assurez vous de bien suivre les instructions donnees dans cette notice pour r duire au minimum le risque d incendie ou d explosion ou pour viter tout dommoge mat riel toute blessure ou la mort Ne pas entreposer ni utiliser d essence ou ni d autres vapeurs ou liquides inflammables proximit de cet appareil ou de tout autre appareil QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ Ne pas tenter d allumer d appareil Ne touchez aucun interrupteur ne pas vous servir des t l phones se trouvant dans le b timent e Appelez imm diatement votre fournisseur de gas depuis un voisin Suivez les intructions du fournisseur e Si vous ne purvez rejoindre le fournisseur appelez le service des incendies L installation et l entretien doivent tre assur s par un installateur ou un service d entretien qualifi ou par le fournisseur de gaz Table of Contents BEFORE YOU START WARNING This manual must be read and fully Before YOU Start 2 understood before installing operating or servicing J this boiler Failure to fol
13. GVIOM 5R GV100W NATURAL OR PROPANE GAS BOILER INSTALLATION amp OPERATING INSTRUCTIONS BS DESIGNED AND TESTED ACCORDING TO A S M E BOILER AND PRESSURE VESSEL CODE SECTION IV FOR MAXIMUM ALLOWABLE WORKING PRESSURE OF 50 PSI 345 kPa WATER NOTE TO INSTALLING CONTRACTOR READ THESE INSTRUCTIONS CAREFULLY THEY WILL SAVE YOU TIME IN ASSEMBLING BOILER PROPERLY WARNING Installation and service must be performed by a qualified 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 fire or explosion causing property damage personal injury or loss of life WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damge 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 puilding e immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions f 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 TH
14. HLIWS LON 9 y HOLIMS 3afiSS 4 2 HDIH y g e 9 19YINO9 ON 1 01 9 19VINO9 UN cH AV 138 HILIMS 32IA83S X CII3AA3NDH AO IVANJA 7 ASLVM LOR DOLAS 9070 007 081 ISI 949020 08479 HIZ2 NOLAON aOSN3S 431INDI 19934405 10H qaainoay Sy NOI19310dd GVO143AD NV SNV3A LOANNOISIG 3QIAH d 5 M 3M MO 71134 OV 18 8 3078 18 dO LOW 901 AV 13 301 3Veld xoa NOILINAC L6 e 16809 dWOo 9010 001 0211 ISI 249020 832 NOLAON SIISN3S 313LINDI n H 10 CO BNA an p 1039 40 M M C0 8MA aD 10398 8 IAWA 90 A A 9 9 HILIMS 110 7704 14 HILIMS 596 23 910 16 Z 31435 108109 1 1 amp 43 1 Are L P di L aOLVINDIAID ASH A N HOLIAS L 33IA33S 27 17 D 09 I ASH Page 15 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS FIG NO 15 Multi Zone Diagram FIG NO 16 Multi Zone Diagram T87F ZONE 1 T87F ZONE 3 V8043F V8043F TO ADDITIONAL R845A RELAYS FOR OTHER ZONES LINE VOLTAGE LOW VOLTAGE R8285D R845A RELAY ZONE 1 R8285D LINE VOLTAGE LOW VOLTAGE
15. Louvers 3 x 12 144 000 108 000 36 000 8 x 8 256 000 192 000 64 000 8 x 12 384 000 288 000 96 000 812 x 16 512 000 384 000 128 000 COMMON VENT SYSTEMS WARNING Do not connect this boiler or any other appliance using a mechanical draft system under positive pressure to a common vent system Failure to comply with this warning could result in the accumulation of carbon monoxide gas which can cause severe personal injury or death If an existing appliance is removed from a common venting system the common venting system may then be too large for the proper venting of the remaining appliances connected to it At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation one ata time while the other appliances remaining connected to the common venting system are not in operation Au moment du retrait d une chaudi re existante les mesures suivantes doivent tre prises pour chaque appareil toujours raccorde au systeme d evacuation commun et qui fonctionne alors que d autres appareils toujours raccord s au syst me d vacuation ne fonction nent pas syst me d vacuation 1 Seal any unused openings in the common vent system Sceller toutes les ouvertures non utilis es du sys teme d vacuation 2 Visually inspect the venting system for proper size and horizonal pitch and determine that there is no blocka
16. ce Curve 10 HEAD FEET OF WATER TACO 007 CIRCULATOR PERFORMANCE CURVE FLOW GPM GAS SUPPLY PIPING WARNING All gas piping must be installed by a qualified technician in accordance with the provisions set forth in the latest edition of ANSI 2223 1 54 and all applicable local building codes and regulations A licensed propane installer must make all LP gas connections Improper gas connections could result in a fire or an explosion The GV100W hot water boiler comes from the factory ready to be piped to the gas supply WARNING Check the boiler rating plate and make sure that the boiler is for the type of gas that will be used If it isn t Do not connect the boiler to the gas supply or a fire or an explosion may occur If for any reason the boiler is not for the type of gas available at the installation site call the nearest Smith Cast Iron Boiler distributor to resolve the problem FIG NO 12 depicts the proper way to connect the boiler to the gas supply piping The manual shut off valve MUST be installed in the supply piping It should be approximately 5 ft 1 5 m above the floor Provide a sediment trap drip leg at the bottom of the vertical section of the gas supply pipe A ground joint union should be installed between the boiler gas controls and th
17. cur or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the pump Instead shut off the gas supply at a location external to the appliance En cas de surchauffe ou si l alimentation de gaz ne peut tre coup e ne pas couper ni d brancher l alimentation lectrique de la ponpe Fermer plut t le robinet d admission de gaz l ext rieur de l appareil Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control that has been under water N utilisez pas cet appareil s il a t plong dans l eau m me partiellement Faites inspecter l appareil par un tecnicien qualifi et remplacez toute partie du systeme de contr le et toute commande qui ont t plong s dans l eau Direct Ignition Systems A Connect a manometer having a minimum capacity of 10 in 254 mm WC to the outlet pressure port of the gas valve Make sure that the gas supply piping has been purged of air and that all gas joints up to the gas valve have been thoroughly checked for leaks Wait at least five minutes for the gas to dissipate before turning on the electrical power B Understand and follow the operating instructions on pg 14 of this manual that are applicable to the type of ignition system installed on the boiler C Raise the thermostat at least 5 degrees above the room tempe
18. de CAUTION Never increase the input to the boiler above that for which it is rated Doing so can cause premature failure of the boiler FIG NO 18 Main Burner Flames LIFTING TOO MUCH AIR NORMAL HARD FLAME YELLOW TIPPING MARGINAL YELLOW FLAME TOO LITTLE AIR WARNING Yellow flooating flames indicate a lack of combustion air Do not operate the boiler until the problem is solved or severe personal injury or death may occur Low Water Cutoff If the boiler is equipped with a low water cutoff device make sure that the main burners will NOT light when the boiler has no water in it To check turn the boiler off close the valves in the water supply and return lines and drain the boiler If the boiler s main burners light shut the boiler off immediately and correct the problem Thermostat Adjustment For a thermostat that employs an adjustable heat anticipator adjust the anticipator to match the current measured in the thermostat circuit An increased anticipator setting may be necessary if the unit cycles frequently If the room temperature over shoots the thermostat setting reduce the anticipator setting Page 20 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS BOILER MAINTENANCE WARNING The ceramic combustion chamber in the burner box and its gasket contain crystalline silica Wear a tightly fitted dust mask when servicing the burner and gently handle the burner and its gasket to
19. e boiler It is adjustable from 140 F 60 C to 220 F 104 C If the water temperature reaches the set temperature before the demand for heat has been met the aquastat high limit should shut the burners off The outlet water temperature should never exceed 220 F 104 C If the aquastat high limit fails to function properly replace it 5 Visually check the burner flames See FIG NO 18 INSTRUCTIONS TO THE INSTALLER The installer must give this copy of the INSTALLATION AND OPERATING INSTRUCTIONS to the boiler owner and make sure that the owner or operator has a basic understanding of the following 1 The lighting instructions the type of ignition system installed and how it operates 2 Whatthe labels on the boiler say 3 Howto start up and shut off the boiler 4 Howto turn the gas and electrical power on or off 5 What to do if the boiler ignition system locks out 6 Where to check the system temperature and pressure and what they should be 7 The importance of reading understanding and following these instructions The installer must make sure that the owner knows to shut the boiler off and call for service if the following conditions occur 1 Yellow lazy flames or flames outside the boiler jacket 2 Gas smell or other strange odors 3 Discoloration of the boiler or surrounding materials due to overheating 4 Water leaking from the heating system piping or relief valve 5 Flue products leaking from t
20. e supply piping Each of these items are needed to ensure long life and ease of servicing Always use a pipe sealant that is suitable for use with LP gas CAUTION Always use a wrench on the gas valve body when making gas connections to it Never over tighten the piping entering the gas valve body Failure to comply with this caution may result in gas valve failure FIG NO 12 Gas Supply Piping GAS INLET INSTALL MANUAL SHUT OFF VALVE 5 FT ABOVE FLOOR WHERE REQUIRED BY LOCAL CODES GAS SUPPLY PIPING ae GROUND JOINT UNION fi Jue TO V BOILER Scie im TO EXTEND TO FLOOR E Table 3 should be used to ensure that the gas supply piping is sized properly If more than one appliance is supplied by the same supply pipe the piping must be sized based on the maximum possible demand Do not neglect the pressure drop due to pipe fittings Table 4 should be used in conjunction with Table 3 to ensure that the gas supply piping is sized properly FLOOR LEVEL Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in ANSI Z21 13 CAN 4 9 All gas connections must be leak tested before putting the boiler into operation WARNING Never use an open flame to test for gas leaks Always use an approved leak detection method Failure to comply with this warning could result in an explosion Wh
21. easurement of the room temperature Locating the thermostat behind a door in an alcove close to a source of thermal radiation or in a drafty area will cause poor or sporadic heating CO DETECTORS WARNING Installers must follow local regulations with respect to the installation of CO detectors and follow the manufacturer s stated maintenance schedule for this boiler ATTENTION Observer les r glements r gional l egard des d tecteurs de monoxyde de carbone et observer entretien de manufacturier pour cette chaudi re DNISIA 2401994 M J 705109 ISH SVNIN331 1N31VAIn03 5 11 AO JAIA JILSVIdOWSSHL 9 S0 HLIA 32V d3 8 38 LSNW LI I39V1d3 8 38 LSNW 32NVIdddv SIHL 31 1ddnS SV JAIA TWNIDIAO 3HL ANY 4 41314 N33 9 D ADnTI3A A ADV 14 18 30194 18 G0 8M aO 10395 3A WA 599 F68S 113AA3NDH M 88 G0 88A AO 10398 JAVA 590 M 9 9 J A 7103 q HE ayaa 1119415 910219373 15 60 IWANI4 LINIAID 91404135373 N HILIMS 110 7704 AWV 14 LVLSOWARHL Are 3591 10A Ao1 71109 28 AV 132 vAog AIWaOASNVAL i ion NEL 3429 1112219 91021953713 9010 001 02111 ISI 249020 0 29 NOLAON YOSN3IS ASLINOI 32V 10H 09 1 AST NLIILLINDI 43294405 FIG NO 13 Fenwal Honeywell Hot Surface Igni Page 14 7041 02 NO STVNIN231 Q NOIZONNT NI S IVNINA31 V
22. ellow colored flames in the appliance e Stale or smelly air e The presence of soot or carbon in or around the appliance Very high unexplained humidity inside the building If any of the symptoms CO poisoning occur or if any of the signs of carbon monoxide are present vacate the premises imme diately and contact a qualfied heating service company the gas company or the fire department To reduce the risk of CO poisoning have your heating system tuned up by a licensed heating contractor or the gas company preferably before each heating season Also have the service company check your chimney or vent pipes for blockage Your home should also be adequately ventilated particularly if you have insulated your home ONLY QUALIFIED LICENSED SERVICE CONTRACTORS SHOULD PERFORM WORK ON YOUR SMITH BOILER Install operate and maintain unit in accordance with manufacturer s instructions to avoid exposure to fuel substances or sub stances from incomplete combustion which can cause death or serious illness The State of California has determined that these substances may cause cancer birth defects or other reproductive harm Also install and service this product to avoid exposure to airborne particles of glasswool fibers and or ceramic fibers known to the State of California to cause cancer through inhalation WESTCAST INC 260 NORTH ELM STREET WESTFIELD 01085 CAST IRON BOILERS TEL 413 562 9631 FAX 413 562 3799
23. en the nuts 4 Reconnect all wires tubing and anything else disconnected during the burner removal operation 5 Complete the reassembly and follow the instructions in the BOILER OPERATION section of this manual Heat Exchanger Cleaning Remove the burners to protect them from falling rust and scale by following the Burner Removal instructions 1 Remove the vent pipe front access and top panels 2 Disconnect the inducer wires and carefully separate the inducer from the flue collector Remove the two flue collector retaining clips Cut the RTV seal and remove the flue collector 4 Clean the flue passages with a wire brush 5 Vacuum out the burner base and clean and inspect the ignition system components Damaged or badly corroded parts must be replaced 6 Remove the old flue collector sealant and reseal the flue collector Use Dow Corning 732 RTV or an equivalent silicone sealant Install the flue collector retaining clips and screws 7 Clean then reseal the inducer using Dow Corning 732 RTV or an equivalent silicone sealant before reattaching it to the flue collector 8 Replace the top panel WARNING The flue collector and inducer must be properly sealed Allow the RTV sealant 24 hours to cure before using the boiler Improper sealing could result in carbon monoxide poisoning 9 Reconnect the inducer wires and the vent system 10 Follow the Burner Installation procedure above 11 Once the sealan
24. enever 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 psig 3 5 kPa isolate the boiler by closing its manual shut off valve see FIG NO 8 If the test pressure is greater than 1 2 psig 3 5 kPa disconnect the boiler and it s individual shut off valve from the gas supply piping Page 13 Page 13 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS TABLE 3 Maximum Gas Pipe Capacity in ft hr Nominal Iron Pipe length Pipe Size 10 20 30 40 50 60 100 150 34 278 190 152 130 115 105 90 79 64 1 520 350 285 245 215 195 170 150 120 11 4 1050 730 590 500 440 400 350 305 250 112 1600 1100 890 760 670 610 530 460 380 Note Maximum pipe capacity in ft3 hr based on 0 60 specific gravity gas at pressures of 0 5 psig or less and 0 3 WC pressure drop TABLE 4 Equivalent Pipe Length Chart Equivalent length of pipe fittings in feet Type of Pipe Fitting Nominal Iron Pipe Size 90 Elbow Tee Gate Valve Gas Cocks branch flow full port 34 2 06 4 12 0 48 1 25 1 2 62 5 24 0 61 1 60 11 4 3 45 6 90 0 81 2 15 11 2 4 02 8 04 0 94 2 50 ELECTRICAL WIRING Electrical Power Connections CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation ATTENTION Au moment de l entretien des commandes tiquetez tous les fils avant de les d brancher De
25. es ventilateurs d t Fermer les registres des chemin es 4 Place in operation the appliance being inspected Follow the lighting instructions Adjust the thermostat so the appliance will operate continuously Mettre l appareil inspect en marche Suivre les instructions d allumage R gler le thermostat de facon que l appareil fonctionne de facon continue 5 Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe Faire fonctionner le br leur principal pendant 5 min ensuite d terminer si le coupe tirage d borde l ouverture de d charge Utiliser la flamme d une allunette ou d une chandelle ou la fum e d une cigarette d un cigare ou d une pipe 6 After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous condition of use Une fois qu il a t d termin selon la m tode indiqu e ci dessus que chaque appareil raccord au systeme d vacuation est mis l air libre de facor ad quate Remettre les portes et les fen tres les ventilateurs les registres de chemin es et les appareils au gaz leur position originale 7 Any improper operation of the common venting system should be corrected so the installatio
26. full OFF position on the White Rodgers 36E push the knob before turning it 7 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above If you don t smell gas go to the next step 8 Turn the gas control knob counterclockwise Y to ON 9 Replace control access panel 10 Turn on all electric power to the appliance 11 Set thermostat to desired setting 12 If the appliance will not operate follow the instructions To turn off gas to appliance and call your service technician or gas supplier PRESSURE REGULATOR ADJUSTMENT SCREW GAS CONTROL KNOB SHOWN IN ON POSITION GAS INLET cM GAS OUTLET PRESSURE REGULATOR ANS CONTROLKNOR ADJUSTMENT SCREW SHOWN IN ON POSITION WHITE RODGERS 36E BEE TO TURN OFF GASTO APPLIANCE Sl 1 Set the thermostat to lowest setting 2 Turn off all electric power to the appliance if service is to be performed 3 Remove control access panel 4 Turn the gas control knob clockwise to OFF On W R controls push the knob in before turning don t force it 5 Replace control access panel Page 17 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS POUR VOTRE S CURIT LISEZ AVANT DE METTRE EN MARCHE A B AVERTISSEMENT Quinconque ne respecte pas la lett
27. ge or restriction leakage corrosion and other deficiencies which could cause an unsafe condition Inspecter de fa on visuelle le syst me d vacu ation pour d terminer la grosser et l inclinaison horizontale qui conviennent et s assurer que le syst me est exempt d obstruction d tranglement de fruite de corrosion et autres d faillances qui pourraient pr senter des risques Page 7 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS 3 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 Turn on cloths dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so that they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers Dans la mesure du possible fermer toutes les portes et les fen tres du b timent et toutes les portes entre l espace o les appareils toujours raccord s du syst me d vacuation sont install s et les autres espaces du b timent Mettre en marche les s cheuses tous les appareils non raccord s au syst me d vacuation commun et tous les ventilateurs d extraction comme les hottes de cuisinere et les ventilateurs des salles de bain S assurer que ces ventilateurs fonctionnent la vitesse maximale Ne pas faire fonctionner l
28. he vent system into the living space Dampness or condensation in the building is a good indicator of this condition 6 The boiler s flame roll out safety system is actuated 7 Control malfunction or sporadic operation Page 22 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS LU LU SIOM 32 GV100 SERIES REPAIR PARTS 7 Number of Sections Top Rear Inner Front and Front Panels gt 2 Left Side Panel 55701 Right Side Panel 55702 Noncombustilbe Floor Pan 4 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS Number of Sections A KEBBE 5 8 Heat Exchanger Assembled Block 8 Burner 69445 2 MN 3_ ese 42 NG co Burner Orifice 54 LP 60177 2 Manifold 1 1 1 mdwedBowr 5682 Ls Gener mme EE v o3 1 16 Roll Out Switch 262 deg F 404257A 60567 1 1 17 Pressure Switch Set W C 1 1 Pressure Switch Set 0 51 W C Pressure Switch Set 0 58 W C Pressure Switch Set 0 65 W C 18 Pressure Retet vate open foss 19 Temp amp Pressure Gauge 60265 HSI FENWALL IGNITION SYSTEM ww Gas Valve 36 01 308 NG 50010 j Gas Valve VR8305M 3506 LP 50057 1 Inducer Relay In
29. ique de la chaudiere Mette le thermostat thermostat sur le r gleage d sir Si l appareil ne fonctionn pas voir les instructions de COUPURE DE L ARRIVE DE GAZ A LA CHAUDIERE et appeler un technicien reparateur ou le fournisseur de gaz Tourner le bouton de commande de gaz vers la droite y en position d arr t OFF Ne pas forcer Heplacer le panneau de parte du r chauffer Page 18 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS BOILER SET UP Note Before starting the boiler turn off the electrical supply going to it Make sure that gas is available at the gas valve inlet Open the valves in the return and supply piping 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 Review these instructions and make sure that the boiler installation complies with all of the instructions up to this point BOILER OPERATION WARNING Before operating read and understand the instructions contained in this manual Do not attempt to operate this boiler if it has not been installed in accordance with the guidelines set forth in this manual Read and fully understand the operating instructions in the For Your Safety Read Before Operating section of this manual pg 14 Failure to comply with this warning could result in a fire or explosion Should overheating oc
30. l metal vent pipe sized per Table 1 Galvanized sheet metal pipe must have a minimum wall thickness of 26 gauge In Canada pipe constructed of 025 in 0 68 mm thick aluminum or 018 inch thick stainless steel may be required The use of thimbles firestops and other protective devices when penetrating combustible or noncombustible construction must be in accordance with all applicable national and local codes WARNING Single wall vent pipe must NEVER pass through interior walls or through floors or ceilings Failure to comply with this warning could result in a fire causing extensive property damage severe personal injury or death An unused chimney flue can be used as a raceway for single wall metal pipe see FIG NO 4A WARNING Never run vent pipe through a chimney flue that has another appliance attached to it Never connect another appliance to a pressurized vent system it must serve only one appliance Failure to comply with this warning can result in excessive levels of carbon monoxide causing severe personal injury or death A listed vent terminal designed for the type of pipe being used must complete the vertical run where it exits the chimney If the chimney is on an outside wall or in an unheated space the optional condensate tee and trap pictured in FIG NO 4A may be required The trap is made by ty rapping a loop in the 3 8 clear plastic tubing attached to the tee and filling it with water Do not operate
31. ll be easier to set accurately In the absence of a flow indicator set the metering valve using temperature as a guide The accompanying diagram suggests one scenario This addition requires only two tees a plug valve and a small amount of pipe and offers the simplest approach to reliably control condensation For this system and those that follow be aware that you are using a percentage of the pump capacity to blend but the friction loss for the entire pump flow has been reduced In most cases the standard pump packaged with the boiler has enough capacity to feed the baseboard distribution system and the bypass line FIG NO 6 RETURN SYSTEM BYPASS Pump Away Bypass For systems that use a single circulator to pump away from the boiler the bypass should be installed on the discharge side of the circulator see FIG NO 7 Full temperature water supplies the baseboard distribution system as before Half of the circulators volume moves through the bypass blending and heating the cooler return water Again the cost of installing the bypass is small and setting it by temperature can be accomplished with a contact thermometer FIG NO 7 RETURN PUMP AWAY BYPASS Page 11 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS Pumped Blend An additional circulator can also be used to provide a return water temperature blend This method works well with systems with multiple zones with circulators see FIG
32. low these instructions could Boiler Ratings 8 Capacities 3 result in a fire or explosion causing extensive Boiler Location 3 property damage personal injury or death Combustible Floor Option 4 These instructions cover the GV100W gas fired induced draft low pressure sectional cast iron hot water boiler GV100W Dimensions amp Component 2 boilers have been design certified by CSA for use with natural and propane gas under the latest edition of ANSI Z21 13 Gas Combustion ane corn Common Vent Systems 6 4 9 Gas Fired Steam and Hot Water Boilers Chimney Vent Pipe Connection f Each unit has been constructed and hydrostatically tested for a maximum working pressure of 50 psi 345 kPa in accor dance with the A S M E Boiler and Pressure Vessel Gas Supply Piping 12 Code Section IV for cast iron boilers Each boiler has been equipped with a 30 psi pressure relief valve Heating System Piping Electrical Wiring 13 This manual covers the application installation operation and 1110 41114261 17 Boiler 19 I To obtain the safe dependable efficient operation and lo
33. n conforms with the National Fuel Gas Code ANSI Z223 1 NFPA 54 When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix F in the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CSA B149 Installation Codes Tout mauvais fonctionnement du syst me d vacu tion commun devrait tr corrig de facor que l installation soit conforme au National Fue Gas Code ANSI Z223 1 NFPA 54 et ou aux codes d in stallation CSA B149 Si la grosseur d une section du syst me d vacuation doit etre modifi e le syst me devrait tr modifi pour respecter les valeurs minimales des tableaux pertinents de l appendice F du National Fuel Gas Code ANSI Z223 1 NFPA 54 et ou des codes d installation CSA B149 CHIMNEY VENTING WARNING This boiler must be vented in accordance with Part 7 Venting of Equipment of the latest edition of the National Fuel Gas code ANSI Z223 1 NFPA 54 and all applicable local building codes In Canada follow CAN CGA B149 1 or 2 Installation Codes Improper venting of this appliance can result in excessive levels of carbon monoxide which can result in severe personal injury or death Chimney Inspection amp Sizing GV100W series boiler can be vented into a masonry chimney FIG NO 4 provided several conditions are met a thorough inspection of the chimney must be performed e the
34. n qualifi et remplacez toute partie du systeme de contr le et toute commande qui ont t plong s dans l eau 1 ARRETEZ Lisez les instructions de s curit sur la portion sup rieure de cette etiquette Mette le thermostat a la temp rature la plus basse Coupez l alimentation lectrique de l appareil Cet appareil est quip d un dispositif d allumage automatique la br leur BOUTON DE COMMANDE DE GAZ MONTR EN POSITION D ARRET ARRIVEE DU GAZ REGULATEUR DE PRESSION Enlever le panneau de parte du rechauffer Tourner le bouton de commande de gaz vers la droite lt w en position d arr t OFF Ne pas forcer Mette le thermostat la temp rature la plus basse Si un entretien doit tre effectu coupez l alimentation lectrique de l appareil Lever le panneau de parte du r chauffer f 11 12 CO PURE DE L ARRIVE DE GAZ A LA CHAUDIERE 4 Attendre cinq 5 minutes pour laisser chapper tout le gaz Reniflez tout autour de l appareil y compris pr s du plancher pour d celer une odeur de gaz Si vous sentez une odeur de gaz ARR TEZ Passez l tape B des instructions de s curit sur la portion sup rieure de cette tiquette S il n y a pas d odeur de gaz passez l tape suivante Tourner le bouton de commande de gaz vers la gauche yk en position de marche ON Replacer le panneau de parte du r chauffer R tablir toute l alimentation lectr
35. ng life Checking amp Adjusting 20 or which this boiler was designed these instructions must be Boiler Maintenance 21 read understood and followed Instructions to the Installer 22 Direct all questions to your Smith Cast Iron Boiler distributor or write to the Customer Service Department 260 North Elm Replacement Parts EP 23 Street Westfield MA 01085 Always include the model and Health Warnings 24 serial numbers from the rating plate of the boiler in question Page 3 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS The owner should maintain a record of all service work performed with the date and a description of the work done Include the name of the service organization for future reference Where required by the authority having jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 The installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the National Fuel Gas Code ANSI Z223 1 latest edition In Canada the installation must be in accordance with the requirements of CAN CGA B149 Installation Code for Gas Burning Appliances and Equipment BOILER RATINGS amp CAPACITIES Before undertaking the installation of the GV100W check the boiler ra
36. nt required at elevations up to 2000 ft 670 m At elevations above 2000 ft 670 m input ratings should be reduced by 4 for each 1000 ft 305 m above sea level Check the input rate as follows Natural Gas 1 Turn off all other gas appliances that use the same gas meter as the boiler 2 Call the gas company for the gas heating value Start the boiler and let it run for 15 minutes 4 Using the gas meter and a stop watch clock the time that it takes to burn 10 cubic feet of gas and divide the time by 10 5 Insert the heating value and the time in seconds into the following formula Heating Value Btu ft 3600 s hr Input Rate How Example If the heating value 1000 Btu ft and the flow rate 36 s ft Input Rate 36 s f Input Rate 100 000 Btu hr If the computed rate deviates by more than 5 from the rated input value of the unit adjust the gas valve pressure accordingly Do not adjust the manifold pressure by more than 5 If a proper rate cannot be maintained without adjusting the manifold pressure beyond the 5 limit the main burner orifices must be replaced If the input rate is too low go to the next larger size orifices If the input rate is too high go to the next smaller size Propane Gas The input rate for LP units is factory set based on the orifice size The manifold pressure must be set at 10 WC and the 54 burner orifices used unless the unit is to be derated for altitu
37. rature A delay of about 30 seconds will take place as the silicon carbide ignitor heats up Once the ignitor is hot the main gas valve will open and the burners should light If the burners fail to light the system will make two more ignition attempts If the burners light but go out within 4 seconds the system will make three ignition attempts If the burners have not lit after the last ignition try the gas valve will close and the system will go into lock out Do not attempt to reset the system until the ignition system has been inspected and the problem resolved Once the problem has been resolved and 5 minutes have passed since the last ignition attempt reset the system by turning the thermostat to it s lowest setting and then back to where it was or by momentarily interrupting the electrical power to the boiler D With the burners in operation close the manual shutoff valve in the gas supply line As soon as the burner flames go out open the manual shutoff valve A normal ignition sequence should take place E With the burners in operation interrupt the power to the control circuit by lowering and raising the thermostat A normal ignition sequence should follow F Totestthe ignition safety shutoff device close the manual shutoff valve in the gas supply line Within 6 seconds of main burner flame extinction the main gas valve solenoid should close with an audible noise The ignitor should glow and an attempt at ignition
38. re les instructions dans la pr sente notice risque de d clencher un incendie ou une explosion entra nant des dommages des blessures ou la mort 1 Cet appareil est muni d ue veilleuse qui doit tre allum e manuellement Respectez lis instructions cidessous a la lettre 2 Cet appareil ne comporte pas de veilleuse Il est muni d un dispositif d allumage qui allume automatique la br leur Ne tentez pas d allumer la br leur manuellement AVANT DE FAIRE FONCTIONNER reniflez tout autour de l appareil pour d celer une odeur de gaz Reniflez pres du plancher car certains gaz sont plus lourds que l air et peuvent s accumuler au niveau du sol QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ Ne pas tenter d allumer d appareil e Ne touchez aucun interrupteur ne pas vous servir des t l phones se trouvant dans le b timent Appelez imm diatement votre fournisseur de gaz depuis un voisin Suives les instructions du fournisseur e Si vous ne pouvez rejoindre le fournisseur appelez le service de incendies C Ne poussez ou tournez la maneette d admission du gaz qu la main ne jamais utiliser d outil Si la manette reste coinc e ne pas tenter de la r parer appelez un technicien qualifi Le fait de forcer la manette ou de la r parer peut d clencher une explosion ou un incendie N utilisez pas cet appareil s il a t plong dans l eau m me partiellement Faites inspecter l appareil par un tecnicie
39. relief equipment and not less than 7 ft 2 3 m from any adjacent public walkway The bottom of the vent terminal s shall be located at least 5 ft 7 5 m above the air intake terminal s ATTENTION Au moment de l entretien des commandes tiquetez tous les fils avant de les debrancher Des erreurs de cablage peuvent entra ner un fonctionnement in ad quat et dangereux S assurer que l appareil fonc tionne ad quatement une fois l entretirn termin The hoizontal vent system must terminate with a Field Controls SK 4G or Breidert L4 vent terminal or a 4 90 elbow fitted with a 1 4 wire mesh debris screen Avoid locations likely to be affected by winds snow drifts people and pets Protect building materials and vegetation from degradation caused by the flue gases HEATING SYSTEM PIPING CAUTION All heating system piping must be installed in accordance with the ANSI ASME Boiler and Pressure Vessel Code Section IV and ANSI ASME CSD 1 Standard for Controls and Safety Devices for Automatically Fired Boilers All applicable local codes and ordinances must also be followed If the boiler is installed above any radiation elements it must be fitted with a low water cutoff device installed above the normal boiler water level The GV100W hot water boiler comes from the factory ready to be piped to the heating system Each boiler is equipped with a safety relief valve which must be piped in accordance with the ANSI ASME Boiler and
40. s erreurs de c blage peuvent entrainer un fonctionnement in ad quat et dangereux S assurer que l appareil fonc tionne ad quatement une fois l entretirn termin The electrical connections to this boiler must be made in accordance with all applicable local codes and the latest edition of the National Electrical Code ANSI NFPA 70 Installation should also conform with CSA C22 1 Canadian Electrical Code Part if installed in Canada Install a separate 120 volt 15 amp circuit for the boiler A shut off switch should be located at the boiler The boilermust be grounded in accordance with the authority having jurisdiction or if none the latest edition of the National Electrical Code ANSI NFPA 70 Line voltage field wiring of controls and other devices must conform to the temperature limitation of type T wire at 95 F 35 C above room temperature Use copper conductors with a minimum size of 14 awg Low voltage wiring must not be less than 18 awg with a neoprene thermoplastic or other equivalent insulation having a minimum insulation thickness of 0 012 in 0 3 mm THERMOSTAT INSTALLATION Always follow the instructions included with the thermostat to be used to control the boiler Proper location of the thermostat will ensure efficient trouble free operation of the boiler Mount the thermostat to an inside wall at a height approximately five feet above the floor Avoid placing the thermostat in areas that will not provide an accurate m
41. supported and each connection securely fastened with at least 3 corrosion resistant sheet metal screws The termination of the vent pipe must be flush with the inside of the chimney flue Always provide a minimum clearance of 6 in 752 mm between single wall metal vent pipe and any combustible materials Type B1 vent may be used clearance between it and any combustible material must be as listed WARNING Failure to maintain minimum clearances between vent connectors and combustible materials can result in a fire causing extensive property damage severe personal injury or death FIG NO 4 Chimney Venting CHIMNEY LINER THIMBLE ARAN VENT SYSTEM e Ta Uu Ta Um a laala ala aa aa BOILER CLEANOUT TR LR RR RR VERTICAL VENTING B Vent The boiler may be vented vertically using the proper size Type B1 vent pipe Do not use the boiler as a load bearing element The vent system must be fully supported by the building structure Use an approved vent terminal at the vent outlet which must extend at least 3 ft 7 above the highest point where it passes through the roof In addition the vent pipe must be at least 2 ft 0 6 m higher than any portion of the building within a horizontal distance of 10 ft 3 m Single Wall Metal Vent GV100W boilers may be vented vertically using single wal
42. t has cured fire the boiler to make sure that it operates properly Vent System At least once a year the entire vent system must be thoroughly inspected for any signs of blockage corrosion or leaks Immediately replace any unsound vent system piping Remove any foreign matter in or near the vent terminal or around the boiler that might obstruct the flow of combustion and ventilation air Inspect the condensate trap if installed for blockage and clean if necessary Every 3 to 6 months lubricate the inducer motor using 2 drops of 20W non detergent motor oil in each oil port WARNING Failure to properly inspect the vent system on a regular basis may leave problems undetected that can result in excessive levels of carbon monoxide which can cause severe personal injury or death Page 21 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS Controls Burners Refer to the BOILER OPERATION and CHECKING and ADJUSTMENT sections in this manual 1 Check the thermostat for proper operation 2 If the boiler has been equipped with a low water cut off device L W C O ensure that it operates properly A float type L W C O should be flushed out relief valve should vent water when the test lever is lifted It should not weep or discharge water at normal system pressure Never try to clean or repair the relief valve If the valve fails replace it 4 The aquastat high limit controls the maximum water temperature in th
43. t panels or damage to the boiler may result Make sure that the special base support channels are squarely under the boiler base side panels Carfully slide the boiler and base into position Center the boiler from side to side and ensure that the back of the burner base side panels are flush with the back of the Special Base support channels Install the front grill supplied with the Special Base Complete the boiler installation in accordance with the instructions set forth in this manual Page 5 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS FIG NO 1 Minimum Clearances to Combustible Construction Clearances A B C D E F Alcove in 25 5 6 4 7 4 mm 635 152 102 178 102 Closet in 25 2 6 4 7 4 mm 635 51 152 102 178 102 To Service in N A N A 6 4 10 10 mm 157 102 254 254 No front wall for alcoves FIG NO 2 Boiler Dimensions amp Component Locations 0 2 11 16 m lt B 8 5 8 18 6 1 2 w al 211 16 1 PRESS D BB 7 SWITCH
44. take place After unsuccessfully attempting to light the main burners the ignition module should lock out Open the manual shutoff valve in the gas supply line Reset the ignition control system by interrupting then restoring electrical power to the boiler A normal ignition sequence should take place Page 19 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS CHECKING amp ADJUSTMENT Gas Pressure Adjustment Natural Gas Optimum results are obtained when the boiler is operated at its full input rating with 3 5 in 89 mm WC of manifold pressure The manifold pressure should not be more that 5 off this value The gas valve pressure regulator has been preset at the factory If adjustment is necessary the following steps must be followed 1 Attach a manometer to the pressure tap on the gas valve body 2 Remove the regulator adjustment screw cap from the gas valve body 3 Rotate the regulator adjustment screw clockwise to increase the manifold pressure counterclockwise to decrease it Never force the regulator adjustment screw or the gas valve will be damaged 4 Replace the regulator adjustment screw cap and pressure tap plug Propane Gas A manifold pressure of 10 0 in 254 mm WC must be maintained for proper operation of the boiler the manifold pressure is off by more than 5 adjust it according to steps 1 through 4 above Input Rate Gas appliances are rated based on sea level operation with no adjustme
45. that the boiler has seven sections Therefore the proper special base would be Part No CB100 7 If the model number has a 3 order special base Part No CB100 3 etc If the GV100W is being installed in an alcove or closet ensure that the distances between the boiler and all combustible construction are greater than or equal to the minimum distances listed in FIG NO 1 CAUTION Take care not to damage the burners pilot or any other gas train components during this procedure If a component is damaged it must be replaced Determine the best boiler location by following the instructions in the BOILER LOCATION section of this manual Remove the front access panel and position the boiler in front of this location leaving room behind the boiler to work Tightly thread a 1 1 4 elbow onto the close nipple in the supply pipe so the opening faces the front of the boiler Thread a 4 length of 11 4 pipe into the elbow and carefully lift the front of the boiler Slide a 3 thick brick or block under the first 1 of each boiler base side panel Make sure the boiler is steady and won t shift to the side Remove the 4 length of pipe Rotate the 1 1 4 elbow so it s opening faces the back of the boiler Thread the 4 length of pipe or a shorter one if necessary back into the elbow Place the special base behind the boiler Using extreme care lift the boiler up and slide the special base under the boiler CAUTION Never lift the boiler by the jacke
46. 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 What to do if you smell gas e Do not try to light any appliance Do not touch any electric switch do not use any phone in your building E IIISTSSIIZISIISTIQITITIIIkH I I IZI ZII II II OPERATING INSTRUCTIONS 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 C Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water DIRECT IGNITION HONEYWELL VR8305 AND WHITE RODGERS 36E NATURAL PROPANE GAS 1 STOP Read the safety information on previous page 2 Set the thermostat to lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand 5 Remove control access panel 6 Turn the gas control knob clockwise to the
47. the boiler without this trap FIG NO 4A Vertical Venting Through a Chimney ny CHIMNEY THIMBLE CONDENSATE DRAIN ASS Y aa aaa SYSTEM aa a as BOILER z Page 9 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS HORIZONTAL VENTING Horizontal vent systems must be in compliance with UL 1738 for installations in the United States ULS636 for installations in Canada For best results horizontal vent systems should be as short and straight as possible The 4 adapter must be attached directly to the boiler outlet A vertical vent run at least 18 inches high must be installed before any horizontal run begins If the boiler is installed using a 3 diameter vent system a 4 to 3 diameter reducer must be installed after the 18 inch vertical run The previously mentioned vent system manufacturers have the proper adapters and reducers available The vent system must be both gas tight and watertight All seams and joints in metal pipes must be joined and sealed in accordance with the vent system manufacturers instructions When horizontal vent runs exceed 5 feet they must be supported at 3 foot intervals with overhead hangers FIG NO 4B Horizontal Venting 4 MIN THIMBLE
48. ting plate to ensure that the boiler is the proper size for the job The Net I B R Ratings specify the equivalent amount of direct cast iron radiation that the boiler can handle under normal conditions Also ensure that the boiler has been set up for the type of gas available at the installation site Other important considerations are the availability of an adequate electrical supply fresh air for combustion and a suitable chimney or vent system location BOILER LOCATION WARNING This boiler is for installation on non combustible floors only A special base supplied by the manufacturer must be used to install this boiler on a combustible floor Failure to comply with this wwwwarning could result in property damage severe personal injury or death 1 Locate the boiler in an area that provides good access to the unit Keep in mind that servicing may require the removal of jacket panels Accessibility clearances must take precedence over fire protection clearances 2 optimum site will be level central to the hot water piping system close to a chimney or outside wall and have adequate fresh air for combustion Ensure that the floor is structurally sound and will support the weight of the boiler This boiler is designed for non combustible floors only A special base supplied by Smith Cast lron Boilers must be used if the boiler is to be installed on a combustible floor Never install this boiler on carpeting 4
49. verse aquastat m REVERSE AQUASTAT SET AT 120 F circulator 24 volts M operating aquastat 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 FIG NO 10 for the proper piping layout When a boiler is connected to a heating coil that may be exposed to refrigerated air from an air handling device the piping system must be equipped with flow control valves or some other automatic means of preventing gravity circulation of the boiler water during the cooling cycle FIG NO 10 Chiller Schematic NOTE FOR HEATING VALVES H OPEN VALVES C CLOSED FOR COOLING VALVES H CLOSED VALVES C OPEN EXP TANK RELIEF VALVE DRAIN DRAIN BOILER CHILLER Page 12 GV100W BOILER INSTALLATION amp OPERATING INSTRUCTIONS Circulators The TACO 007 circulator supplied with the boiler is sized for use in a closed heating system with a 30 psi 207 kPa maximum operating pressure If the 007 circulator does not have the required capacity for the system in which it is to be installed an extra zone circulator or a higher capacity circulator will be needed FIG NO 11 depicts the performance curve for the TACO 007 circulator FIG NO 11 TACO 007 Performan
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