Smith Cast Iron Boilers GB250 SERIES User's Manual
Contents
1. CONTROL SECONDARY PRESSURE po s GAS VALVE IF ANY OF THE ORICINAL WIRE AS SUPPLIED WITH THE BOILER MUST BE REPLACED USE A SIMILAR WIRE OF 105 RATING 115 24V PE TRANSF H N 115 V AC 115v 24V E ME A LWCO M ME PRESSURE T STAT OR BURNER CONTROL OPER CNTRL s r 1 NENT PI TM E 29 GAS VALVE x 5 o Ape ni SECONDARY PRESSURE CONTROL FJ SAS AVE NATURAL GAS 8 amp 9 SECTION 60394 FIGURE 2 18 WIRING DIAGRAM 8 OPERATION SEQUENCE FOR BOILERS EGUIPPED WITH STANDING PILOT VENT DAMPER amp 400 SERIES LWCO GB250 8 amp 9 ONLY SECTION 3 START UP amp OPERATION SEGUENCE OF OPERATION For seguence of operation of the particular boiler being installed refer to Figures 2 13 through 2 18 in Section 2 of this manual Spill and rollout switches are mounted on Model GB250 5L GB250 5H and GB250 6 boilers For boilers with a spill switch the switch detects the escape of combustion products through the draft diverter relief opening and interrupts the power to the gas valve preventing unsafe boiler operation Escape of flue products could be caused by a blocked or collapsed chimney or inadequate chimney draft This is a manual reset type device and can be reactivated by depressing the spill switch reset button mounted on the left of the bo2. GB250 SERIES INSTALLATION OPERATION amp MAINTENANCE MANUAL AND REPLACEMENT PARTS LIST Gas Fired Steam Cast Iron Boilers 175 000 to 400 000 Btuh Input Standing Pilot Standing Pilot amp Vent Damper Intermittent Pilot Intermittent Pilot amp Vent Damper SECTION 1 INTRODUCTION Step 6 Wiring Boiler Code Compliance 2 Venting Requirements 3 SECTION 3 START UP amp OPERATION Chimney Requirements 3 Sequence Of Operation Combustion Air Reguirements 3 Prior To Start Up Water Treatment 4 Start Up 8 Adjustments Shipment of Boiler sss 4 SECTION 4 MAINTENANCE SECTION 2 BOILER INSTALLATION Before Each Heating Season Step 1 Locating Setting Boiler 5 How To Change Orifices Step 2 Installing Steam Piping 6 Heating System Problems amp Causes Step 3 Installing Hydronic Components 7 Replacement Parts List Step 4 Venting Boiler 7 Warnings Step 5 Installing Testing Gas Piping 10 GB250 IM 5 42 9185 Smith
3. P 2e MV PV NERA TH TR PV GND ROLLOUT le l SWITCH o Z4 GND 4 5 o 24 IGNITER SENSOR be SPARK SPILL AND ROLLOUT SWITCHES ON 3 THRU 6 SECTION ONLY 60393 FIGURE 2 16 WIRING DIAGRAM amp OPERATION SEQUENCE FOR BOILERS EGUIPPED WITH INTERMITTENT PILOT VENT DAMPER 8 400 SERIES LWCO OPERATING SEQUENCE FOR SREAM BOILERS EQUIPPED WITH STANDING PILOT VENT DAMPER HI LIMIT amp CG 400 SERIES LWCO REMAINS CLOSED DURING STANDBY STANDING PILOT REMAINS LIT MOTOR DRIVES VENT DAMFER TO CLOSED POSITION AND SENSING CIRCUIT 15 CONTINUOUSLY MONITORED THERMOSTAT OR OPERATING CONTROL CALLS FOR HEAT DAMPER BLADE OPENS DAMPER END SWITCH CLOSES PROVING DAMPER OPEN MAIN VALVE IS ENERGIZED UNIT OPERATES UNTIL THERMOSTAT OR OPERATING CONTROL IS SATISFIED 9 SYSTEM RETURNS TO STANDBY WITH DAMPER CLOSED DU ON PU FU FIELD WIRING 777777777 THERMOSTAT FACTORY WIRING O OR OPER LOW WATER ica SENTRAL CUTOFF PRESSURE B RU CONTROL 2 1 P1P2 A NER eli p spo ge SPILL i 5 SWITCH i del P TRANSF LR BEK item eee ze a RED 194 GAS VALVE VENT 4e4 MET o TR DAMFER RED 5 i ROLLOUT SWITCH IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE BOILER MUST BE REPLACED USE A SIMILAR WIRE OF 105
4. FIELD WIRING FACTORY WIRING PRESSURE CHNTISUE OR OPERATING CONTROL 115 24V IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 05 C WIRE OR ITS EQUIVALENT 115 24V PRESSURE SPILL CONTROL SWITCH Lweg STAT UR ROLLOUT SWITCH GAS VALVE SPILL AND ROLLOUT SWITCHES USED WHEN INPUT IS LESS THAN 300 000 BTUH 42 5736 REV 2 FIGURE 2 13 WIRING DIAGRAM amp OPERATION SEQUENCE FOR BOILERS EQUIPPED WITH INTERMITTENT PILOT VENT DAMPER amp MCDONNELL MILLER 67 LOW WATER CUT OFF 13 FIGURE 2 14 WIRING DIAGRAM amp OPERATION SEQUENCE FOR BOILERS EQUIPPED WITH STANDING PILOT VENT DAMPER amp MCDONNELL MILLER 67 LOW WATER CUT OFF EXCEPT FOR GB250 8 amp GB250 9 N G OPERATING SEQUENCE FOR STEAM BOILERS EQUIPPED WITH STANDING PILOT VENT DAMPER HI LIMIT E C O amp 67 LWCO MOTOR DRIVES VENT DAMPER TO CLOSED POSITION AND REMAINS CLOSED DURING STANDBY STANDING PILDT REMAINS LIT SENSING CIRCUIT IS CONTINUOUSLY MONITORED THERMOSTAT DR OPERATING CONTROL CALLS FUR HEAT DAMPER BLADE OPENS DAMPER END SWITCH CLOSES PROVING VENT DAMPER OPEN MAIN VALVE IS ENERGIZED 8 UNIT OPERATES UNTIL THERMOSTAT COR OPERATING CONTROL IS SATISFIED 9 SYSTEM RETURNS STANDBY WITH DAMPER CLOSED FIELD WIRING FACTURY WIRING PRESSURE 67 CONTROL LWCO THERMDSTAT OR OPERATING BLUE 7 BLUE CONTROL
5. PROVING DAMPER OPEN IF NO FAILURE EXISTS THE PILOT VALVE AND IGNITER ARE ENERGIZED PILOT IS IGNITED AND SENSOR SENSES FLAME MAIN VALVE IS ENERCIZED AND IGNITER DE ENERGIZED 9 UNIT OPERATES UNTIL THERMOSTAT OR OPERATING CONTROL IS SATISFIED 10 SYSTEM RETURNS TO STANDBY WITH DAMPER CLOSED QU UN FIELD WIRING 9 THERMOSTAT FACTORY WIRING 0 LOW WATER CONTROL CUTOFF PRESSURE SGT TT CONTROL 2 1 P4 P2 A NER sela o OO SPILL 1 5 SWITCH 115 24V PRA sue TRANSF V pu BLK pec WHT m 115v 60HZ ak H rF GAS VALVE E 58600 MV m o MV TR MV PV REO n BLK TH TR PV 1 o GND WHT 4 DAMPER RED alone BLUE IGNITER 5 ROLLOUT SPARK SwitcH SENSOR IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE BOILER MUST BE REPLACED USE A SIMILAR WIRE OF 105 C RATING H N a 115 V AC 115V 24V FE bb ud LWCO AV o m p TB Te bese CO seni SWITCH PRESSURE T STAT OR 2a tee OPER CNTRL mae a DAS VALVE Em VENT NE 4 Lo MV IDAMPER TR MV PV E o o
6. When an existing boiler is removed from common venting system common venting system is likely to be too large for proper venting of appliances remaining connected to it At time of removal of existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while other appliances remaining connected to the common venting system are not in operation 1 Seal all unused openings in common venting system 2 Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 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 clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers 4 Place in operation the appliance being inspected Fo llow the lighting instructions Adjust thermostat so appliance will operate continuously 5 Test for spillage at draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from cigare
7. 2 5 If vent damper is supplied with boiler it must be installed between the top of the draft hood and the flue pipe See Installing The Vent Damper instructions Connect draft hood to chimney or Class B vent Flue pipe must be same diameter as the draft hood outlet The flue or vent connectors must be installed flush with the inside chimney liner surface and sealed in place with furnace cement Horizontal portions of the single wall and type B venting systems shall be supported by use of strap hangers or their eguivalent Vent supports should be placed a maximum of 15 feet apart and as reguired to prevent sagging The vent connectors shall be pitched 1 4 per foot upwards towards the chimney or vent termination DANGER Only the boiler may be served by the vent damper Do not attempt to use it to vent an additional appliance This will cause fire or carbon monoxide poisoning Installing Vent Damper The vent damper must be mounted directly on top of the draft hood Locate the motor on the front side and position the cable so that it does not touch the metal surface of the drafthood see Figure 2 6 If necessary turn angle connector on vent damper upward until cable clears tighten locknut to secure The direction of the flow arrow imprinted on the vent damper must point upward The damper position indicator which is located on the side of the vent damper opposite the motor must be visible CAUTION A minimum of 6 betwe
8. 30 Transformer 120 24V 43VA 50172 1 1 1 1 1 1 22 Honeywell Intermittent Pilot System Pilot Ass y N G Q3451B 1103 72354 Pilot Ass y N G Q3451B 1103 70003 1 Pilot Ass y N G Q3451B 1103 72355 1 Pilot Ass y N G Q3451B 1103 72356 Pilot Ass y N G Q3451B 1103 72357 Pilot Ass y L P Q3451B 1103 72360 Pilot Ass y L P Q3451B 1103 72361 Pilot Ass y L P Q3451B 1103 70008 Gas Valve N G VR8304P 4332 59136 Gas Valve L P VR8304P 3340 59137 Gas Valve L P VR8304P 4330 59138 Ignition Control S8600M 1013 51177 Ignition Cable 36 Lg 59308 Transformer 120 24 1006 43VA 50172 REF GB250 GB250 GB250 GB250 GB250 GB250 NO NAME OF PART PART NO 5L 5H 6 7 8 9 6 1 1 23 ASSEMBLY E 26 31 o CHO 27 24 WARNING 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 Brief exposure to high concentrations of CO or prolonged exposure to lesser amounts of CO may result in carbon monoxide poisoning Exposure can
9. C RATING WHT 115V BOHZ H N 115 115V 24V en ences ut oit PILL SWITCH PRESSURE T STAT OR CONTROL OPER CNTRL xw VENT V 1 5 1 MEE 2 ROLLOUT GAS VALVE also SWITCH 4N gt b Ap b NATURAL GAS Z THRU 7 SECTION LP GAS 3 THRU 9 SECTION SPILL amp ROLLOUT SWITCHES ON 3 THRU 6 SECTION ONLY 60392 FIGURE 2 17 WIRING DIAGRAM amp OPERATION SEQUENCE FOR BOILERS EQUIPPED WITH STANDING PILOT VENT DAMPER amp 400 SERIES LWCO EXCEPT FOR GB 250 8 amp 9 15 OPERATING SEQUENCE FOR SREAM BOILERS EQUIPPED WITH STANDING PILOT VENT DAMPER HI LIMIT ECO e CG 400 SERIES LWCO 1 MOTOR DRIVES VENT DAMPER TO CLOSED POSITION AND REMAINS CLOSED DURING STANDBY STANDING PILOT REMAINS LIT SENSING CIRCUIT IS CONTINUOUSLY MONITORED THERMOSTAT OR OPERATING CONTROL CALLS FOR HEAT DAMPER BLADE OPENS DAMPER END SWITCH CLOSES PROVING DAMPER OPEN o x O U B UN MAIN VALVE IS ENERGIZED UNIT OPERATES UNTIL THERMOSTAT OR OPERATING CONTROL IS SATISFIED 9 SYSTEM RETURNS TO STANDBY WITH DAMFER CLOSED FACTORY WIRING LOW WATER CUTOFF NH BUR 2 1 P4 P2 A NER P O o 0 C 2 FIELD WIRING SEU 1 PRESSURE CONTROL THERMOSTAT OR OPER CONTROL p BLUE GAS VALVE WHT VENT RED o TR DAMPER o TH
10. ELECTRIC LWCO important information concerning the product DANGER Indicates an imminently hazardous situation which if not avoided will result in death serious injury or substantial property damage WARNING Indicates a potentially hazardous situation which if not avoided could result in death serious injury or substantial property damage The following terms are used throughout this manual to bring attention to the presence of potential hazards or to CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor injury or property damage NOTE Used to notify of special instructions on installation operation or maintenance which are important to equipment but not related to personal injury hazards VENTING REGUIREMENTS When connecting to gas vents or chimneys vent instal lations shall be in accordance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 latest edition or applicable provisions of the local building codes For Canada the provisions of B149 1 and B149 2 shall apply Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechani cal draft systems operating under positive pressure When two or more appliances vent into a common flue the area of the common flue should be at least equal to the area of the largest flue plus 5096 of the areas of the additional flue or vent connectors
11. TO CLOSED POSITION AND REMAINS CLOSED DURING STANDBY SENSING CIRCUIT IS CONTINUOUSLY MONITORED DAMPER BLADE OPENS DAMPER END SWITCH CLOSES PROVING DAMPER IF NO FAILURE EXISTS THE PILOT VALVE AND IGNITER ARE ENERGIZED PILOT IS IGNITED AND SENSOR SENSES FLAME MAIN VALVE IS ENERGIZED AND IGNITER DE ENERGIZED UNIT OPERATES UNTIL THERMOSTAT OR OPERATING CONTROL IS SATISFIED SYSTEM RETURNS TO STANDBY WITH DAMPER CLOSED FIELD WIRING FACTORY WIRING PRESSURE 5 CONTROL TO MV PV TW o IF ANY THE ORIGINAL WIRE AS SUPPLIED WITH THE BOILER MUST BE REPLACED USE A SIMILAR WIRE OF 105 C RATING 115 V AC 15V 24V ROLLOUT SWITCH MANUAL RESET SPILL T STAT DR SWITCH E UPER CNTRL PRESSURE CONTROL SPILL AND RULLUUT SWITCHES USED WHEN INPUT IS LESS THAN 300 000 BTUH THERMOSTAT OR OPERATING CONTROL CALLS FOR HEAT 42 5702 REV 4 OPERATING SEQUENCE FOR STEAM BOILERS EQUIPPED WITH STANDING PILOT VENT DAMPER HI LIMIT amp 67 LWCO MOTOR DRIVES VENT DAMPER TO CLOSED POSITION AND REMAINS CLOSED DURING STANDBY STANDING PILOT REMAINS LIT SENSING CIRCUIT IS CONTINUOUSLY MONITORED THERMOSTAT lt OR OPERATING CONTROL CALLS FOR HEAT DAMPER BLADE OPENS DAMPER END SWITCH CLOSES PROVING VENT DAMPER OPEN MAIN VALVE IS ENERGIZED UNIT OPERATES UNTIL THERMOSTAT UR OPERATING CONTROL IS SATISFIED SYSTEM RETURNS TO STANDBY WITH DAMPER CLOSED
12. 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 WARNING Install operate and maintain unit in accordance with manufacturer s instructions to avoid exposure to fuel substances or substances 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 25 26 27 m WESTCAST INC S 260 NORTH ELM STREET WESTFIELD MA 01085 CAST IRONBOLERS TEL 413 562 9631 FAX 413 562 3799 www smithboiler com
13. be fatal and exposure to high concentrations may result in the sudden onset of symptoms including unconsciousness 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 Flames coming out around the appliance Yellow colored flames in the appliance Stale or smelly air 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 immediately 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
14. in accordance with National Fuel Gas Code ANSI Z223 1 latest edition and all applicable local codes In Canada follow CAN CGA B149 1 or 2 installation codes PROCEDURE B FIGURE 2 1 Check minimum m f mi iy aiaj i clearances to Ii e combustibles are proper as shown Local SENT TOP requirements may specify greater clearances amp must be za adhered to Wn e En yiil Boiler shall be install m 10 K anes 12 ed such that the gas go RECOMMEND 2 og MORE FOR ignition system com ACCESS TO P ponents are protected POSITION UH from water dripping INDICATOR spraying rain etc during appliance oper ira ation and service 1 gt mm gt 52 FOR GB250 S 5L THRU GB250 5 7 58 FOR GB250 S 8 THRU GB250 S 9 WARNING Never install boiler on combustible flooring without combustible flooring pan or on carpeting as heat damage and or fire may result CAUTION Locate boiler so horizontal connecting flue pipe is as short as possible Maximize height of vertical flue connector NOTE Do not loosen tie rods on absorption unit They accommodate thermal
15. other chimney upgrades Check with local utility for required safety precautions COMBUSTION AIR REQUIREMENTS Provisions for combustion air must be in accordance with the National Fuel Gas Code ANSI Z223 1 latest edition as well as all applicable local codes If the boiler is installed in an unconfined space adequate air will be available via normal infiltration However if building construction is unusually tight or the boiler is installed in a confined space a space whose volume is less than 50 cubic feet per 1000 Btu hr of gas input for all fuel burning equipment adequate air for combustion must be provided by two openings one located about 6 below the ceiling the other about 6 above the floor When communicating directly with the outside or through a vertical duct each opening must have a minimum free area of one square inch per 4000 Btu hr of gas input Horizontal ducts to the outside must have a minimum free area of one square inch per 2000 Btu hr of gas input When ventilation is provided by openings in doors etc to adjoining spaces having adequate infiltration each opening must have a minimum free area of one square inch per 1000 Btu hr of gas input WARNING Adequate fresh air must be provided for combustion Improper boiler operation and inadequate venting of deadly flue gases may otherwise result NOTE Boiler employs atmospheric combustion Combustion air must not be contaminated with halogenated hydrocarbon
16. utility 7 If input needs to be corrected adjust combination gas valve pressure regulator Regulator is factory set at 3 1 2 W C for natural gas and 10 W C for propane Turn adjusting screw clockwise to increase gas flow increase input Turn adjusting screw counterclockwise to decrease gas flow decrease input In no case should final manifold pressure setting vary more than 3 from factory set pressures lf rated input cannot be obtained with adjustment gas supply pressure or orifice size may be cause Consult local utility and Smith 8 Gas burner orifices supplied with boiler have been carefully designed to provide correct gas input rate for most gas conditions typically found in the U S and 17 Canada Occasionally however local gas characteristics may not allow unit to be properly adjusted for input If this is the case local utility or Smith may recommend orifices be changed When changing orifices follow the procedures detailed in Section 4 of this manual 9 Start and stop burners several times by raising and lowering the thermostat setting 10 After boiler has been firing long enough to raise boiler pressure above minimum setting of the primary pressuretol limit check limit by turning its setting from maximum to minimum setting This should turn boiler off Return limit to desired setting GB250 8 and GB250 9 also have a secondary pressuretrol located to the right of the primary pressuretrol when facing
17. vapors aerosol propellants or freon Otherwise boiler heat exchanger will be subject to corrosion reducing boiler life WATER TREATMENT Water treatment is recommended in areas where water quality is a problem A local water treatment company should be consulted to determine the requirements for your particular system and locality NOTE Boiler is not for use in systems where water is replenished Minerals in the water can build up on the heat transfer surfaces and cause overheating and subseguent failure of the heat exchanger NOTE Boiler utilizes synthetic rubber seals Water treatment chemicals and system cleaning chemicals must be compatible with this and all other construction materials SHIPMENT OF BOILER Each boiler is shipped in a single carton Draft hood is shipped in a separate carton on larger models Optional Vent Damper When ordered the vent damper is shipped in an individual carton packaged with the boiler Mounting of the damper is required 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 reglemenis regional a Vegard des d tecteurs de monoxyde de carbone et observer entretien de manufacturier pour cette chaudiere SECTION 2 BOILER INSTALLATION STEP 1 LOCATING AND SETTING THE BOILER PROCEDURE A Check that provisions for combustion air
18. 417 1275 1180 1086 1023 967 866 787 2 6221 4331 3465 2992 2646 2394 2205 2047 1921 1811 1606 1498 300 000 Btu per hour 1 000 Btu per cu ff z 300 cu ft per hour Example Boiler Model GB250 7 is to be installed The distance from the existing gas meter installation site is 20 feet What pipe size must be used The local utility indicates the heating value of the natural gas being supplied is 1 000 Btu per cubic foot Determine the cubic feet of gas per hour for above boiler model 1 Find 20 ft in the upper portion of the table for natural gas under Length of Pipe Feet heading 2 Moving down the column match the required capacity The higher capacity is acceptable In our case it is 350 cu ft 3 Move to the left hand column Nominal Iron Pipe Size Inches to read required pipe size In our case it is 1 FIGURE 2 10 10 Testing Gas Piping DANGER Before placing gas piping into service carefully test it to assure every joint is gas tight Bubble test all joints with a soap solution NEVER TEST WITH AN OPEN FLAME AS EXPLOSION WILL RESULT FIRE OR For any pressure testing in excess of 1 2 psi the boiler and its individual shutoff valve must be isolated from the piping system by disconnecting them and capping the outlet s For any pressure testing egual to or less than 1 2 psi the boiler must be isolated from the piping system by closing its manual shutoff valve Minimum pressure required at the gas valv
19. 9 SPILL 1 SWITCH U5 24V TRANSF _ PURO 4 WHT o zs BLK 115V AC poe Le BLK 1 sadne jer 3 O SZ la BLUE bos ROLLOUT SWITCH l STR GAS VALVE L J ECO GAS VALVE SECONDARY PRESSURE CONTROL IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH TYPE MTW 05 C WIRE OR ITS EQUIVALENT L1 Le 115V AC 115 24V PRESSURE SPILL N CONTROL SWITCH Lwco UR pan p e OPER CNTRL fi aj 71 3e TH TR gt GAS VALVE Gas VALVE E CDU PRESSURE CONTROL SPILL AND ROLLOUT SWITCHES USED WHEN INPUT IS LESS THAN 300 000 BTUH 42 5745 REV 1 FIGURE 2 15 WIRING DIAGRAM amp OPERATION SEQUENCE FOR BOILERS EQUIPPED WITH STANDING PILOT VENT DAMPER amp MCDONNELL MILLER 67 LOW WATER CUT OFF FOR GB250 8 amp GB250 9 N G 14 OPERATING SEOUENCE STEAM BOILERS EQUIPPED WITH VENT DAMPER CG 400 SERIES LWCO AND IID 1 MOTOR DRIVES VENT DAMPER TO CLOSED POSITION AND REMAINS CLOSED DURING STANDBY SENSING CIRCUIT IS CONTINUOUSLY MONITORED THERMOSTAT DR OPERATING CONTROL CALLS FOR HEAT DAMPER BLADE OPENS DAMPER END SWITCH CLOSES
20. ACKET TRANSFORMER GAS VALVE DK BLUE v THERMOSTAT CONNECTION FIGURE 2 6A Vent Damper Installation for Standing Pilot LOWER lll PORTION OF l 1 VENT DAMPER H HZ TO DRAFTHOOD OUTLET WITH 1 2 OR SHORTER SCREWS OR POP RIVETS sa FIGURE 2 8 PROCEDURE C Install flue pipe between vent damper and chimney 6 minimum clearance required between flue pipe and combustibles USE VENT SUPPORT S AS REQUIRED TO PREVENT SAGGING ZON N iaxImUM SINGLE WALL la 6 FT OR TYPE B APART FLUE PIPE A h PITCH 1 4 PER FOOT SECURE FLUE PIPE TO VENT DAMPER INSTALL FLUSH WITH CHIMNEY j LINER SEAL WITH FURNACE CEMENT FIGURE 2 9 ADDITIONAL VENTING REQUIREMENTS When connecting to gas vents or chimneys vent installations shall be in accordance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 latest edition or applicable provisions of the local building codes Vent connectors serving appliances ven
21. Close fireplace dampers 4 Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously 5 Test for spillage at draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from cigarette cigar or pipe 6 After it has been determined that each appliance remaining connected to common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to previous conditions of use 7 Any improper operation of the common venting system should be corrected so installation conforms with the National Fuel Gas Code ANSI Z223 1 latest edition 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 G in the National Fuel Gas Code ANSI Z223 1 latest edition For Canada the provisions of CAN CGA B149 1 or 2 shall apply ADDITIONAL CHIMNEY REQUIREMENTS Chimney condition is of paramount importance for a safe and efficient boiler installation All installations must include a chimney inspection by a qualified individual or agency Chimney construction materials must be compatible with the fuel being used Particular attention should be paid on all oil to gas conversions Soot may have accumulated in c
22. INSTALL BURNERS WITH BURNER PORTS ON THE TOP SURFACE UPRIGHT 5 When low water cut off has been utilized follow the manufacturer s maintenance instructions As a minimum test the operation of electronic controls at least once a year Remove clean and inspect the probe If the LWCO fails to operate properly it must be replaced Float type controls should be flushed once a month during the heating season 6 Follow System Start Up amp Adjustments procedures in Section 3 of this manual Steam Boiler Cleaning Instructions The following procedures must be followed on initial start up and if the presence of sediment sludge or impurities hamper proper boiler operations 1 With gate valves closed on supply and return lines start burner and allow boiler to become pressurized so that the pressuretrol may be adjusted and set for limit cut off desired normally about 3 psi Turn off burner and allow pressure to drop to O psi then proceed with the following cleaning procedure 2 Remove the pressure relief valve 3 Add caustic soda lewis lye through this opening at the rate of one pound per thousand square feet of radiation capacity Scout Squirk or similar steam boiler cleaners may be used instead of lye Trisodium phosphate 1 44 is also an excellent cleaner 4 Provide pipe connection full size from pressure relief valve opening to a convenient drain to serve as a vent 5 Fill the boiler with a manual fill valve u
23. WESTCAST INC CAST IRON BolLeRs TEL 413 562 9631 FAX 413 562 3799 www smithboiler com 260 NORTH ELM STREET WESTFIELD MA 01085 SECTION 1 INTRODUCTION CODE COMPLIANCE Boiler installations 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 Where required by the authority having jurisdiction the installation must also conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 All electrical wiring must be in accordance with National Electric Code ANSI NFPA No 70 latest edition and any additional state or local code requirements If an external source is utilized boiler when installed must be electrically grounded in accordance with requirements of the authority having jurisdiction or in the absence of such requirements with the National Electrical Code ANSI NFPA No 70 latest edition UL listed power limited circuit cable is almost universally approved for safety controls on heating equipment either internally or externally without protection of conduits or raceway For Canada the installation must be in accordance with Standards CGA B149 1 and B149 2 Installation Codes for Gas Burning Appliances and Equipment and or local codes All electrical connections are to be made in accordance with Standard C S A C22 1 Canadian Electrical Code Part 1 and or loca
24. chnician or gas supplier Pons ou oO ON INLET eI OFF GAS CONTROL KNOB GAS 2 v SHOWN IN ON POSITION WR 36C74 GAS CONTROL KNOB SHOWN IN OFF POSITION Honeywell VR8304 TO TURN OFF APPLIANCE 1 Set the thermostat to lowest setting 2 Turn off all electric power to the appliance if service is to be performed 3 Turn gas control knob counterclockwise to OFF Do not force SECTION 4 MAINTENANCE This boiler has been designed to provide years of trouble free performance in normal installations Examination by the homeowner at the beginning of each heating season and in mid heating season should assure continued good performance In addition the boiler should be examined by a gualified service professional at least once every year DANGER To avoid fire and explosion hazards Do not store anything against the boiler or allow dirt or debris to accumulate in the area immediately surrounding the boiler Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liguids Lint paper or rags must not be allowed to accumulate near the burners Do not place clothing on boiler to dry NOTE Do not draw water from heating system for cleaning Minerals in the water can build up on the heat transfer surfaces and cause overheating and subseguent failure of the cast iron sections NOTE Do not obstruct the flow of combustion and ventilation a
25. e inlet is 5 W C for natural gas and 11 W C for propane Maximum pressure allowable at the gas valve inlet is 12 W C If the gas pressure is above these limits a pressure regulator must be installed If the gas pressure is below these limits contact the local utility RISER TO OTHER A APPLIANCES BEAM na PIPE CLAMP GAS MANUAL MAIN METER SHUT OFF VALVE A FIGURE 2 11 UNION SEDIMENT TRAP N STEP 6 WIRING THE BOILER WARNING Turn off electrical power supply before servicing Contact with live electric components can cause electric shock or death All electrical and control wiring must be installed in ac cordance with the codes listed in Section 1 of this manual Follow the wiring diagram for your particular installation as shown in Figures 2 13 through 2 18 GB250 8 and GB250 9 natural gas standing pilot units have a secondary pressuretrol located to the right of the primary pressuretrol when facing the front of the boiler Connect wiring assemblies provided on boiler from the low water cut off or transformer to the primary pressure control and from the gas valve to the secondary pressure control as shown in Fig 2 12 Do not readjust the secondary pressuretrol its purpose is to interrupt thermocouple po
26. en vent damper and combustible materials must be maintained The vent damper must be accessible for servicing and checking position indicator Remove hairpin shipping clip which holds damper blade in closed position and observe that damper blade rotates slowly to open position Do not force it closed as it may damage the gear train and void the warranty The blade should move freely and without obstruction Secure the vent damper housing to the drafthood outlet with sheet metal screws or pop rivets Refer to Figure 2 8 for fastener locations Install flue pipe over top of vent damper and secure to damper housing with sheet metal screws or pop rivets Attach vent damper cable to cable clamp on boiler left panel and join the Molex connector see Figure 2 6 or Figure 2 6A FLOW DIRECTION ARROW POINTS UP MAKE SURE LOCATED ON 4 B MOTOR IS M FRONTSIDE MOUNT VENT DAMPER OVER MN 4 DRAFTHOOD FIGURE 2 7 dii LI PRESSURE VENT DAMPER CONTROL f DRAFTHOOD THERMOSTAT CONNECTION CABLE BRACKET TRANSFORMER PILOT CONTROL DK BLUE X THERMOSTAT CONNECTION FIGURE 2 6 Vent Damper Installation for Intermittent Pilot PRESSURE VENT DAMPER DRAFTHOOD THERMOSTAT CONNECTION CABLE BR
27. expansion Loss of boiler structural integrity and water leaks damage may result Step 1 Continued On Next Page PROCEDURE Check component positioning 1 Remove all packing material from boiler 2 Install on non combustible floor only unless local codes permit use and fabrication of a fireproof base see Fig 2 2 3 Check that burners and controls are in the proper position 4 HOLLOW CLAY TILE TWO COURSES OPENINGS THRU BLOCKS IN TOP COURSE TO BE AT 900 ANGLE TO OPENINGS THRU BOTTOM COURSE _ IN TI 6 OVERHANG OF BLOCK AND SHEETMETAL ALL AROUND 22 GAUGE 0 E SHEETMETAL FLOOR FIGURE 2 2 STEP 2 INSTALLING STEAM PIPING Typical piping connections are shown in Figure 2 3 All external piping must be supported by hangers not by the boiler or its accessories Supply outlet must run full size from boiler to a header at least 24 above top of boiler Condensate return piping should be connected to boiler through a Hartford Loop Install gate valves in supply and return STEAM NIPPLE 3 NPT HARTFORD LOOP RETURN TAPPING 5 WA TER FILL SUPPLY TAPPING Proper steam piping practices must be followed at all times Maintain proper clearances between piping and combustible material The supply and return lines should be equipped with drain cocks to d
28. fire or explosion may result 1 Check combination gas valve on boiler and make sure it is in the OFF position 2 For vent damper eguipped models with the thermostat set to call for heat observe that vent damper position indicator rotates to the open position Damper must be in the open position when appliance main burner is operating a After damper opens spark should appear at the pilot ignition electrodes b Set thermostat to no longer call for heat Spark should stop Observe that damper position indicator rotates to the closed position c Set thermostat to call for heat 3 Light the boiler For Model GB250 boilers with standing pilot see lighting instructions for Continuous Pilot on page 18 For Model GB250 boilers with intermittent pilot see lighting instructions for Intermittent Pilot on page 18 4 Observe pilot and main burner flame see Figure 3 2 All burner ports should be ignited and burn with a steady blue flame FIGURE 3 2 Q3451B Q314A Q309A INTERMITTENT CONSTANT PILOT IGNITION PILOT MODELS 5 d o NORMAL PILOT FLAME SEX NORMAL LIFTING HARD FLAME TOO MUCH AIR YELLOW TIPPING MARGINAL MAIN BURNER FLAMES YELLOW FLAME TOO LITTLE AIR 16 CAUTION Never leave the job with yellow burning flames This condition indicated poor combustion and will guickly carbonize the boiler reducing efficiency and boiler life It may also be an
29. he brass orifice see Figure 4 1 Size can also be checked by using a pin gauge 4 All orifices are screwed into the manifold and may be removed by using a 5 8 wrench or socket 5 Reverse procedures above to install orifices and burners BE SURE TO REINSTALL BURNERS WITH BURNER PORTS ON TOP SURFACE UPRIGHT FIGURE 4 1 Boiler HEATING SYSTEM PROBLEMS amp CAUSES No Heat 1 Blown fuse or circuit breaker 2 Switch turned off 3 Pilot outage 4 IID system malfunction 5 Flue damper not open 6 Water level too low Insufficient Heat 1 Incorrect thermostat anticipator setting 2 Low pressuretrol setting 3 Boiler undersized or underfired 4 Insufficient radiation Odor Excessive Moisture In Building 1 Leak in piping 2 Carbon build up in flueways 3 Blocked chimney Yellow Flame Carbon Build Up 1 Unit overfired 2 Air shutter misadjustment 3 Wrong orifices 4 Burning in burner mixing tube Noise 1 Ignition or ignition noise due to incorrect air shutter adjustment 2 Whistle due to burr on orifices 3 Burner fluting due to air shutter opening too wide Overheating 1 Wrong thermostat anticipator setting 2 Bad thermostat location 3 Bad thermostat GB250 5L GB250 5H GB250 6 GB250 7 GB250 8 GB250 9 Model 1 Nat Gas Drill Size 94 32 2 Prop Gas Drill Size 92 50 31 50 33 32 32 51 51 50 CAUTION Label all wires prior to disconnection w
30. hen servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing 20 Smith CAST IRON BOILERS MODEL GB250 SERIES REPLACEMENT PARTS LIST ORDERING INFORMATION When ordering replacement parts provide the model and serial number shown on the unit rating plate as well as the part number and name as shown in the parts list Parts may be obtained from your local Smith heating contractor NAME OF PART PART NO Jacket Complete Jacket Complete Jacket Complete Jacket Complete Jacket Complete Base Pan Base Pan Base Pan Base Pan Base Pan Burner N G L P Burner w Pilot Bracket N G L P Base Door Ass y Base Door Ass y Base Door Ass y Base Door Ass y Base Door Ass y Manifold Manifold Manifold Manifold Manifold Burner Orifice No Burner Orifice No Burner Orifice No Burner Orifice No Burner Orifice No REF GB250 GB250 GB250 GB250 GB250 GB250 NO NAME OF PART PART NO 5L 5H 6 7 8 9 13 Section Rear 3672 1 1 1 1 1 1 14 Section Intermediate 3671 3 3 4 5 6 7 15 Section Front No Coll Opening 3670 1 1 1 1 1 1 16 Heat Exchanger Assembled Block 72403 1 1 Heat Exchanger Assembled Block 72404 Heat Exchanger Assembled Block 72405 Heat Exchanger Assembled Block 72406 Heat Exchanger Assembled Block 72407 Port Seal 5 60306 Port Seal 2 59168 Pipe Pl
31. himney and or degraded chimney liner Most utilities require complete chimney cleaning Others may require installation of new liner spill switches or other chimney upgrades Check with local utility for required safety precautions DANGER A chimney which does not meet modern safety standards will result in a fire or deadly carbon monoxide poisoning of the building residents STEP 5 INSTALLING amp TESTING GAS PIPING Connect the gas piping from the meter to the boiler using a pipe size which will result in a pressure drop of less than 0 3 W C for natural gas or 0 5 W C for propane See Figure 2 10 for the appropriate gas pipe sizing and example Good piping practices should be followed at all times See Figure 2 11 for a typical gas piping arrangement All piping must be supported by hangers not by the boiler or its accessories Install a full sized sediment trap at the low point in gas line upstream of gas valve Install a non restrictive lubricated plug valve in the gas line close to the boiler Install a ground joint union at the gas valve inlet to allow for servicing Check local codes and utilities for any special reguirements and procedures Pipe joint compound pipe dope must be compatible with the fuel natural gas or propane being used Maximum Capacity of Pipe in Cubic Feet of Natural Gas per Hour for Gas Pressures of 0 5 Psig or Less and a Pressure Drop of 0 3 Inch Water Column Based on a 0 60 Specif
32. ic Gravity Gas Nominal Iron Pipe Internal Length of Pipe Feet Size Diameter Inches Inches 20 30 40 50 60 70 80 90 100 125 150 175 200 1 4 326 32 22 18 15 14 12 11 11 10 9 8 8 7 6 3 8 493 72 49 40 34 30 27 25 23 22 21 18 17 15 14 1 2 622 132 92 73 63 56 50 46 43 40 38 34 31 28 26 3 4 824 278 190 152 130 115 105 96 90 84 79 72 64 59 55 v 1 049 520 350 285 245 215 195 180 170 160 150 130 120 110 100 1 1 4 1380 1 050 730 590 500 440 400 370 350 320 305 275 250 225 210 1 1 2 1 610 1 600 1 100 890 760 670 600 560 530 490 460 410 380 350 320 2 2 067 3 050 2 100 1 650 1 450 1 270 1 150 1 500 990 930 870 780 710 650 610 2 1 2 2 469 4 800 3 300 2 700 2 300 2 000 1 850 1 700 1 600 1 500 1 400 1 250 1 130 1 050 980 3 3 026 8 500 5 900 4 700 4 100 3 600 3 250 3 000 2 800 2 600 2 500 2 200 2 000 1 850 1 700 4 4 026 17 50012 000 9 700 8 300 7 400 6 800 6 200 5 800 5 400 5 100 4 500 4 100 3 800 3 500 Maximum Capacity of Pipe in Thousands of Btu per Hour of Undiluted Liguefied Petroleum Gases at 11 Inches Water Column Inlet Pressure Based on a Pressure Drop of 0 5 Inch Water Column Nominal Iron Pipe Length of Pipe Feet ci 10 20 30 40 50 60 70 80 90 100 125 150 Inches 1 2 275 189 152 129 114 103 96 89 83 78 69 63 3 4 567 393 315 267 237 217 196 185 173 162 146 132 1 1071 732 590 504 448 409 378 346 322 307 275 252 1 1 4 2205 1496 1212 1039 937 834 771 724 677 630 567 511 1 1 2 3307 2299 1858 1559 1
33. iler s draft hood see Figure 2 1 for switch location For boilers with a flame rollout switch the switch prevents flame rollout from the boiler combustion chamber caused by blocked boiler flue passageways by interrupting power to the gas valve to prevent unsafe boiler operation This is a manual reset type device and can be reactivated by depressing the rollout switch reset button mounted on the lower front jacket panel Flue passages must be inspected by a qualified installer if this problem occurs prior to resetting the button WARNING If boiler cannot be restored to normal operation after re setting of spill switch or if flame rollout switch has tripped do not attempt to put the boiler in operation Immediately contact a gualified service professional PRESSURE PRESSURE CONTROL RELIEF VALVE PRESSURE GAUGE WATER LEVEL INDICATOR GAS VALVE 2 tas FIGURE 3 1 PRIOR TO START UP Fill system with water until the water level indicator sight glass is approximately 2 3 full This water level is 23 from the surface on which the boiler sits SYSTEM START UP amp ADJUSTMENTS 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 221 13 WARNING Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids Otherwise
34. indication of improper venting or combustion air supply lf unable to adjust flame properly consult your local utility 5 Boilers are shipped from the factory with the primary air shutters on the main burner wide open t is recommended these air shutters be left in the wide open position unless there is lifting of the flame above the burner ports If there is lifting the air shutters should be gradually closed until the lifting is eliminated it may also be necessary to adjust the primary air shutters if the input rate is reduced by a change in the orifices 6 After burner has been in operation for about 10 minutes check gas input rate to boiler as follows a Make sure all appliances served by the meter are turned off during timing of gas input rate to the boiler b Measure the time in seconds that it takes for the boiler to use 10 cubic feet of gas Divide 36 000 by the number of seconds this is the number of cubic feet of gas used per hour Multiply this figure by the heating value of the gas to obtain Btu input per hour Example A GB250 7 boiler takes 2 minutes to use 10 cubic feet of natural gas The local utility indicated the heating value of the natural gas being supplied is 1000 Btu cu ft Therefore 2 minutes 120 seconds 36 000 120 X 1000 300 000 Btu hr Therefore the boiler input is correct NOTE Before calculating the input of the heating equipment obtain the heating value of the gas from the local
35. ir NOTE If boiler is equipped with a low water cutoff follow manufacturer s maintenance instructions BEFORE EACH HEATING SEASON 1 Remove and inspect draft hood and vent piping connecting draft hood to chimney or vent for obstructions soot accumulation rust or corrosion Clean and replace as necessary Check tightness of joints seal all joints where necessary 2 Check boiler flue passageways in the boiler sections for any blockage or soot accumulation Remove draft hood jacket top and flue collector Using a flashlight examine all flue passageways a If passageways are free of soot and obstructions replace flue collector and seal with furnace cement b If passageways need cleaning remove burners as described in paragraph 3 below Insert long handle bristle flue brush down between section tubes and upward through sections from combustion chamber in both diagonal directions to remove carbon from finned surfaces Vacuum debris Replace flue collector and seal with furnace cement c Reinstall jacket top panel and draft hood 19 3 Check and clean burner assembly Remove burner access panel Lift burners up and to rear until burners are disengaged from orifices Brush top of burners with soft bristle brush and blow out with air or vacuum 4 Check gas manifold for proper position and reassemble burners to the manifold Line up holes in burners with the orifices and slide assembly back into position BE SURE TO RE
36. l codes BOILER DIMENSIONS FOR MODELS SUPPLIED WITH VENT DAMPER ADD 3 5 8 TO DIM E MODEL A B c D E GB250 S 5L 221 2 18 10 1 2 7 25 GB250 S 5H 221 2 18 10 1 2 7 25 GB250 S 6 26 21 1 2 121 2 8 30 GB250 S 7 29 1 2 25 14 8 30 GB250 S 8 291 2 281 2 151 2 9 37 GB250 S 9 36 1 2 32 17 1 2 9 37 i SPILL SWITCH Lor f A ia PRESSURE CONTROL L i L E PRESSURE RELIEF VALVE 3 STEAM 93 amp 4 d Sneed i Q SUPPLY 2 GAUGE 8 19 16 1 2 PLUGGED 3 4 PLUGGED 1 po TAPPING TAPPING THE 7 EN e j 2 m ff e WEE WATER e 811 27 CUT OFF A ONES Sre 33 4 21 2 I li 26 7 8 ez WE 28 1 4 LI ROLLOUT SWITCH 23 7 8 28 1 2 2 p 1 23 1 4 20 vi und TRANSE 2 RETURNO 115 24V REAR 14 3 4 k 18 1 4 GAS VALVE 17 LG xe o Lu 1 I 16 1 2 6 3 4 A 18 1 8 2 RETURN 21 7 8 FRONT LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW PROBE LOCATION FOR
37. n and it will pop back up Pilot should remain lit If it goes out repeat steps 4 through 9 If button does not pop up when released stop immediately and call your service technician or gas supplier If the pilot will not stay lit after several tries turn the gas control knob to OFF and call your service technician or gas supplier 10 Replace the base door 11 Turn gas control knob counterclockwise to ON 12 Turn on all electric power to the appliance 13 Set thermostat to desired setting INLET GAS CA ON GAS CONTROL KNOB SHOWN IN ON POSITION WR 36C04 OPERATING INSTRUCTIONS Intermittent Ignition White Rodgers 36C74 Honeywell VR8304 STOP Read the safety information on this page Set the thermostat to lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand Turn gas control knob clockwise to OFF Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you then smell gas STOP Follow A in the safety information on page 18 If you don t smell gas go to next step Turn gas control knob counterclockwise to ON Turn on all electric power to the appliance Set the thermostat to the desired setting If the appliance will not operate follow the instructions To Turn Off Appliance and call your service te
38. ntil water starts to trickle from this pipe 6 Fireboiler at sufficient rate to generate and maintain steam Entrained water and impurities will then discharge with steam from open vent Add water as necessary so that the low water cutoff does not shut off burner 7 Continue this process for a minimum of one hour The process should continue until the steam is dry no water coming from the vent when the water in the gauge glass is at a normal level approximately 2 3 full The time reguired could vary up to 3 hours 8 Turn burner to off position While boiler is still hot drain completely through boiler drain Make sure that all low points in the return line are also completely drained These areas could trap chemicals and dirt 9 Close boiler drain and refill with clean untreated warm water If warm water is not used fill very slowly so as not to crack boiler sections Fill until water overflows through vent pipe and runs clear 10 Completely drain boiler again Refill with clean untreated water to normal level 11 Remove vent drain piping and reinstall pressure relief valve Open gate valves on supply and return lines Turn on burner System is now ready to operate HOW TO CHANGE ORIFICES 1 Shut off power supply and gas supply to the boiler 2 Remove burner access panel Lift burners up and to rear until burners are disengaged from orifices 3 Check orifices for proper drill size Size is stamped onto the body of t
39. rain sediment and sludge from lowest points of boiler 24 MIN WATER LINE Y h C L OF HARTFORD LOOP TOBE 2 BELOW WATER LINE 1 4 T KT if e wo FIGURE 2 3 STEP 3 INSTALLING HYDRONIC COMPONENTS A low water cutoff must be installed to protect the unit from dry fire Screw extension nipple into 3 4 tapping on top of the absorption unit and install relief valve into top of nipple with the spindle in the vertical position i e with the valve discharge in the horizontal See Figure 2 4 WARNING No Valve of any type may be installed between the boiler and the relief valve to prevent accidental explosion from overpressure Most localities require the discharge piping to terminate within 6 of the floor Check local code requirements if in doubt Discharge piping must be of same size or larger than the relief valve outlet and should be run as short and straight as possible Elbows in the discharge piping should be placed as close to the valve as possible If valve discharge is to be drained away the discharge piping must not be hard piped to the drain piping i e an open funnel or similar arrangement must be used CAUTION Piping must be in
40. s 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 LIGHTING CONTINUOUS PILOT INSTRUCTIONS Standing Pilot Honeywell VR8300 and White Rodgers 36C04 Natural or Propane Gas This appliance has a pilot which must be lit by hand When lighting the pilot follow these instructions exactly STOP Read the safety information on this page Set the thermostat to lowest setting Turn off all electric power to the appliance Turn gas control knob clockwise to OFF For WR 36C04 Push in gas control slightly and turn clockwise to OFF unless knob is pushed in slightly Do not force 5 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you then smell gas STOP Follow A in the safety information above If you don t smell gas go to the next step 6 Remove the base door covering the top of the burners and enclosing the pilot 7 Find pilot Follow metal tube from gas control The pilot is between the central burner tubes behind the base door 8 Turn knob on gas control counterclockwise to Pilot mom GAS CONTROL KNOB SHOWN IN OFF POSITION Honeywell VR8300 RESET BUTTON 9 Push down and hold the red button Immediately light the pilot with a match Continue to hold the red button down for about one 1 minute after the pilot is lit Release butto
41. stalled from the relief valve discharge so there will be no danger of scalding personnel PRESSURE RELIEF VALVE 17 PRESSURE RELIEF VALVE DISCHARGE PIPING STEP 4 VENTING BOILER DANGER Drafthood vent outlet and vent damper as supplied must not be altered in any was as proper boiler operation would be jeopardized Flame rollout fire or carbon monoxide poisoning will result Install draft hood on boiler If the draft hood shroud has a hole near the relief opening for installing a spill switch mount draft hood so the hole faces to the front of the boiler Spill switches are provided on Model GB250 5L GB250 5H and GB250 6 boilers Applicable boiler is equipped with a factory mounted spill switch harness mounting bracket assembly spill switch is provided in plastic bag See Figure 2 5 Install mounting bracket on outside surface of draft hood shroud with screws provided HARNESS MUST BE ON OUTSIDE OF SHROUD Install spill switch in hole in shroud on outside surface with screws provided Plug wiring leads from harness bracket assembly onto flat terminals on spill switch NOTE Boiler will not operate unless wiring leads to spill switch are connected FIGURE 2 4 N Z N INSTALL CONNECT INSTALL SWITCH WIRE MOUNTING IN OPENING LEADS BRACKET PA ENE ON DRAFTHOOD A xu IE des T u ul FIGURE
42. ted by natural draft shall not be connected into any portion of mechanical draft Systems operating under positive pressure When two or more appliances vent into a common flue the area of the common flue should be at least equal to the area of the largest flue plus 5096 of the areas of the additional flue or vent connectors When an existing boiler is removed from a common venting System common venting system is likely to be too large for proper venting of appliances remaining connected to it At time of removal of existing boiler following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while other appliances remaining connected to common venting system are not in operation 1 Seal all unused openings in common venting system 2 Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 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 clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan
43. the front of the boiler DO NOT READJUST THE SECONDARY PRESSURETROL it is factory set and sealed at 15 psig 11 Check boiler safety shutoff controls a For boilers with standing pilot with boiler firing disconnect thermocouple lead from the valve The valve should close b For boilers with intermittent pilot with boiler firing disconnect wire connected to the PV terminal on the Honeywell S8600 control The gas valve should close 12 On initial start up and prior to each heating season boiler must be cleaned see Steam Boiler Cleaning Instructions in Section 4 of this manual WARNING If you do not follow these instructions exactly a fire or explosion may result with property damage personal injury or loss of life A BEFORE OPERATING smell all around 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 Donottry to light any appliance Do not touch any electrical switch do not use any phone in your building Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department B 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 C Do not use this appliance if any part ha
44. tte cigar or pipe 6 After it has been determined that each appliance remaining connected to common venting system proper ly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to previous conditions of use 7 Any improper operation of the common venting sys tem should be corrected so the installation conforms with National Fuel Gas Code ANSI Z223 1 latest edition 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 G in the National Fuel Gas Code ANSI Z223 1 latest edition For Canada the provisions of B149 1 and B149 2 shall apply DANGER A chimney which does not meet modern safety standards will result in a fire or deadly carbon monoxide poisoning of the building residents CHIMNEY REGUIREMENTS Chimney condition is of paramount importance for a safe and efficient boiler installation All new and replace ment installations must include a chimney inspection by a qualified individual or agency Chimney construction materials must be compatible with the fuel being used Particular attention should be paid on all oil to gas con versions Soot may have accumulated in chimney and or degraded chimney liner Most utilities require complete chimney cleaning Others may require installation of new liner spill switches or
45. ug 2 Sq Hd 61547 Low Water Cut Off CG400 50090 Pigtail 1 4 CG400 61684 Pressuretrol 404 50493 Press Gauge 0 15 P S I 60268 Water Gauge 59199 Pressure Relief Valve 15 P S I 61980 Flue Collector 59204 Flue Collector 59205 Flue Collector 59206 Flue Collector 59207 Flue Collector 59208 Draft Hood 7 For Spill Switch 59216 Draft Hood 8 For Spill Switch 59217 Draft Hood 8 59218 Draft Hood 9 59219 Junction Box 4 x 4 60178 Silicone Sealant 11 oz 40440 3 8 Fiberglass Rope 5 Ft Block to Base Seal 80924 Vent 7 Ass y 69496 Vent Damper 8 w Harness Ass y 69497 Vent Damper 9 w Harness Ass y 69498 Cable Bracket 59270 Manual Reset Spill Switch 59273 Manual Reset Rollout Switch 59274 Imu mu mu OOJ a PO 00 S h h i mu ma a IIA i i mu ma a IA Standing Pilot Pilot Ass y N G 0314 3679 72366 Pilot Ass y N G 0314 3679 70004 Pilot Ass y N G 0314 3679 72367 Pilot Ass y N G 0314 3679 72368 Pilot Ass y N P 0314 3679 72369 Pilot Ass y L P 0314 3679 72372 Pilot Ass y L P 0314 3679 70007 Pilot Ass y L P 0314 3679 72373 Thermocouple K16RA 36D 51006 Thermocouple K16RA 48D 59111 Gas Valve N G VR8300C 4043 59131 Gas Valve N G WR36C04 439 59132 Gas Valve L P VR8300C 4035 59133
46. wer to the gas valve in case the primary pressuretrol fails to function FOR FIELD FOR FIELD CONNECTION CONNECTION TO PRIMARY TO SECONDARY PRESSURE PRESSURE CONTROL CONTROL ON THE LEFT ON THE RIGHT WIRE ASSY TRANSFORMER oo GAS VALVE gt FOR BOILERS EQUIPPED WITH MCDONNELL MILLER LWCO FOR BOILERS EQUIPPED WITH MCDONNELL MILLER LWCO FIGURE 2 12 FOR FIELD FOR FIELD CONNECTION CONNECTION TO PRIMARY TO SECONDARY PRESSURE PRESSURE CONTROL CONTROL ON THE LEFT ON THE RIGHT m WIRE ASSY ASSY 400 SERIES ORM amp M PS804 LWCO TRANSFORMER GAS VALVE FOR BOILERS EGUIPPED WITH 400 SERIES OR amp PS804 FOR BOILERS EGUIPPED 400 SERIES OR M amp M PS804 LWCO For vent damper eguipped models connect thermostat to blue leads see Figure 2 6 NOTE If any of original wire supplied with boiler must be replaced use similar wire of 105 rating Otherwise insulation may melt or degrade exposing bare wire NOTE Boiler transformer must not be used to power external accessories i e zone valves relays etc Otherwise transformer will be overloaded and burn out 12 OPERATING SEQUENCE STEAM BOILERS EQUIPPED WITH VENT DAMPER FLOAT TYPE LWCO AND IID MOTOR DRIVES VENT DAMPER
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