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Smith Cast Iron Boilers GB100W manual

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Table of contents for the manual

  • Page 1

    GB100IOM-7 W ARNING: If the inf ormation in this manual is not f ollowed exactly , a fire or explosion may result causing pr oper ty damge, personal injury or loss of life. Do not store or use gasoline or other flammab le vapors and liquids in the vicinity of this or any other appliance . What to do if y ou smell gas: • Do not tr y to light any a[...]

  • Page 2

    Page 2 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS CONTENTS Getting Started page 2 Boiler Ratings & Capacities page 3 Locating the Boiler page 3 Combustible Floor Option page 5 Air for Combustion page 5 Chimney & Vent Pipe Connections page 6 Heating System Piping page 8 Gas Supply Piping page 11 Electrical Wirin[...]

  • Page 3

    Page 3 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS Direct all questions to your Smith Cast Iron Boiler distributor or write to the Customer Service Department, 260 North Elm Street, Westfield, MA 01085. Always include the model and serial numbers from the rating plate of the boiler in question. The owner should maintain[...]

  • Page 4

    Page 4 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS Figure 1: Clearances to Combustible Construction 6 . If the 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 [...]

  • Page 5

    Page 5 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS Figure 2: Special Base Installation on Combustible Flooring COMBUSTION AIR WARNING: This boiler must be supplied with combustion air in accordance with Section 5.3, Air for Combustion & Ventilation, of the latest revision of the National Fuel Gas Code, ANSI Z223.1/N[...]

  • Page 6

    Page 6 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS Input Btuh Input Btuh Input Btuh Fresh Air 1/4" Wire Metal Wooden Duct Size Mesh Screen Louvers 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 8-1/2" x 16" 512,000 384,0[...]

  • Page 7

    Page 7 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS f) 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 previ- ous condition of[...]

  • Page 8

    Page 8 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS Fasten the vent damper to the flue collar and vent pipe using at least 3 corrosion resistant sheet metal screws per joint. Connect the damper harness to the top panel with the BX connector supplied. Plug the Molex connector on the damper harness into the mating plug on [...]

  • Page 9

    Page 9 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS Figure 5: TACO 007 Performance Curve The boiler should be placed in the location selected for it. Refer to the BOILER LOCATION section in this manual. Ensure that the boiler is level from front to back and from side to side. Use metal shims to level the boiler. NEVER us[...]

  • Page 10

    Page 10 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS CAUTION: To prevent damage due to excessive condensation, one of the following piping options should be used. 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 th[...]

  • Page 11

    Page 11 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS GAS SUPPL Y PIPING WARNING: All gas piping must be installed by a qualified technician in accordance with the provisions set forth in the latest revision of ANSI Z223.1 and all applicable local building codes and regulations. All LP gas connections must be made by a li[...]

  • Page 12

    Page 12 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS Figure 11 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 drip leg/sediment trap at the bottom of the vertical se[...]

  • Page 13

    Page 13 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS Figure 12: Fenwal/Honeywell Direct Ignition IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH TYPE 105 ° C THERMOPLASTIC WIRE OR IT'S EQUIVALENT. BK W BL BL BL BL CONTROL CENTER R8285A W/ R8222U RELAY OR 57-01V[...]

  • Page 14

    Page 14 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS Figure 13: Honeywell Intermittent Pilot Ignition IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH TYPE 105 ° C THERMOPLASTIC WIRE OR IT'S EQUIVALENT. BL BL BL BL CONTROL CENTER R8285A W/ R8222U RELAY OR 57-01V[...]

  • Page 15

    Page 15 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS Figure 14: Honeywell Continuous Pilot Ignition IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH TYPE 105 ° C THERMOPLASTIC WIRE OR IT'S EQUIVALENT. BL BL BL BL CONTROL CENTER R8285A W/ R8222U RELAY OR 57-01V18[...]

  • Page 16

    Page 16 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS Figure 17: Multi Zone Diagram CIRCULATOR ZONE 2 LINE VOLTAGE LOW VOLTAGE CIRCULATOR ZONE 1 R882C ZONE 1 THERMOSTAT R882C ZONE 2 THERMOSTAT CIRCULATOR ZONE 3 R882C ZONE 3 THERMOSTAT 1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. 2 Y G W L2 L1 1 POWER SU[...]

  • Page 17

    Page 17 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND 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 combination control inlet. Open the valves in the return and supply piping. Failure to take these precautions will prevent the boiler from[...]

  • Page 18

    Page 18 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS button. The button should pop back and the pilot remain lit. If it goes out repeat steps 5 - 10. * If the button does not pop up when released, stop and immediately call your service technician or gas supplier. * If the pilot will not stay lit after several tries, turn[...]

  • Page 19

    Page 19 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS INSTR UCTIONS D'ALLUMA GE 1. ARRÊTEZ! Lisez les instructions de sécurité sur la portion supérieure de cette étiquette. 2. Réglez le thermostat à la température la plus basse. 3. Coupez l'alimentation électrique de l'appareil. 4. Enlever le panne[...]

  • Page 20

    Page 20 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS T O TURN OFF GAS T O APPLIANCE 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 [...]

  • Page 21

    Page 21 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS POUR V O TRE SÉCURITÉ LISEZ A V ANT DE METTRE EN MARCHE INSTRUCTIONS DE MISE EN MARCHE COÙPURE DE L'ARRIVE DE GAZ A LA CHA UDIERE A VER TISSEMENT . Quinconque ne respecte pas à la lettre les instructions dans la présente notice risque de déclencher un incend[...]

  • Page 22

    Page 22 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS C. Raise the thermostat at least 5 degrees above the room temperature. The burners should light. D. A boiler designed for use with natural gas should have a manifold gas pressure of 3.5" WC. On an LP boiler, the manifold pressure should be 10" WC. To adjust t[...]

  • Page 23

    Page 23 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS 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 [...]

  • Page 24

    Page 24 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS Burner Removal 1. Close the manual shutoff valve in the gas supply line and turn off electrical power to the boiler. 2. Disconnect the boiler ground joint union, see Figure 12. 3. Remove the front access panel. 4. Where applicable, disconnect the wires, pilot tube and [...]

  • Page 25

    Page 25 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS INSTR UCTIONS T O THE INST ALLER This copy of the INSTALLATION AND OPERATING INSTRUCTIONS should be given to the owner of this boiler and kept on file. The INSTALLER must make sure that the owner or operator has a basic understanding of the following: 1. The lighting i[...]

  • Page 26

    Page 26 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS 1 Top, Rear, Inner Front and Front Panels 55703 1 55704 1 55705 1 55706 1 55707 1 55708 1 55709 1 55710 1 55711 1 55712 1 2 Left Side Panel 55701 1 1 1 1 1 1 1 1 1 1 3 Right Side Panel 55702 1 1 1 1 1 1 1 1 1 1 4 Floor Pan 55813 1 55814 1 55815 1 55816 1 55817 1 55818 [...]

  • Page 27

    Page 27 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS 5 Flue Collector/Drafthood 55803 1 55804 1 55805 1 55806 1 55807 1 55808 1 55809 1 55810 1 55811 1 55812 1 6 Heat Exchanger/Assembled Block 69879 1 69880 1 69881 1 69882 1 69883 1 69884 1 69885 1 69886 1 69887 1 69888 1 7 Burner 69445 2 3 4 5 6 7 8 9 10 11 8 Burner Ori[...]

  • Page 28

    Page 28 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS The damper must be mounted as close as possible to the draft hood without modifying the draft hood or damper device. Attach the lower portion of the vent damper to the draft hood with 1/2 in , 13 mm or shorter screws or pop rivets. Do not install within 6 in , 152 mm ,[...]

  • Page 29

    Page 29 LIMITED LIFETIME W ARRANTY FOR RESIDENTIAL W A TER BOILERS This warranty statement is effective for all units manufactured after December 15, 1992 and supersedes all other warranties, including those contained in other documents which might be included with this merchandise. This warranty applies only to the original homeowner at the origin[...]

  • Page 30

    dizziness headaches nausea vision problems loss of muscle control weakness shortness of breath unclear thinking unconsciousness W ARNING 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. I[...]

  • Page 31

    Page 31 GB100W NATURAL OR PROPANE BOILER INSTALLATION AND OPERATING INSTRUCTIONS[...]

  • Page 32

    WESTCAST, INC. 260 NORTH ELM STREET WESTFIELD, MA 01085 TEL. (413) 562-9631 FAX (413) 562-3799[...]