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Smith Cast Iron Boilers GB200 SERIES manual

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Table of contents for the manual

  • Page 1

    GB200-IM-5 42-9184 GB200 SERIES INST ALLA TION, OPERA TION & MAINTENANCE MANU AL WITH REPLA CEMENT P AR TS LIST GAS-FIRED STEAM CAST IR ON BOILERS 85,000 T O 165,000 BTUH INPUT INTERMITTENT PILO T/VENT D AMPER & ST ANDING PILO T/VENT D AMPER SECTION 1: INTRODUCTION Code Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 2

    2 SECTION 1: INTR ODUCTION The f ollowing terms are used throughout this manual to bring attention to the presence of potential hazards or to impor tant inf or mation concerning the product: CA UTION: Indicates a potentially hazardous situation which, if not av oided, may result in minor injury or prop- erty damage . NO TE: Used to notify of specia[...]

  • Page 3

    CHIMNEY REQUIREMENTS D ANGER: A chimne y which does not meet modern safety standar ds will result in a fire or deadly carbon mono xide poisoning of the building residents. Chimney condition is of par amount impor tance for a saf e and efficient boiler installation. All new and replacement installa- tions must include a chimne y inspection by a qual[...]

  • Page 4

    4 FIGURE 2.1: MODEL GB200 BOILER DIMENSIONS PRESS. RELIEF V AL VE B W A TER LEVEL INDICA TOR 2" RETURN FRONT MINIMUM CLEARANCES TO COMB USTIBLES T op: 28" Rear: 18" Left & Right: 18" Front: ALCOVE BOILER MODEL GB200-S-4H GB200-S-4L GB200-S-3 GB200-S-5 DIMENSIONS A 15 3/8" 18 7/8" 18 7/8" 22 3/8" 5" 6[...]

  • Page 5

    5 STEP 2: INST ALLING STEAM PIPING T ypical piping connections are shown in Figure 2.3. All e xter- nal piping must be suppor ted by hangers, not b y the boiler or its accessories. Supply outlet must run full size from the boiler to a header at least 24" abov e top of boiler . Condensate retur n piping should be connected to boiler through a &[...]

  • Page 6

    6 STEP 4: VENTING BOILER A f actor y-mounted spill s witch is provided on all GB200 boil- ers (see Figures 2.4 & 2.4A). The flue or vent connectors m ust be installed flush with the inside chimney liner surf ace and sealed in place with fur nace cement. Horizontal positions of the single wall and type B venting systems shall be supported by use[...]

  • Page 7

    7 FIGURE 2.5: A TT ACHING VENT D AMPER T O DRAFT DIVERTER & FLUE PIPE FLOW DIRECTION ARRO W POINTS UP (REAR VIEW) MAKE SURE MO T OR IS LOCA TED ON FRONT SIDE CLOSED OPEN FLOW DIRECTION MOUNT VENT D AMPER O VER DRAFT DIVER TER INST ALL SWITCH IN OPENING ON DRAFT DIVERTER ADDITIONAL CHIMNEY REQUIREMENTS Chimney condition is of par amount impor ta[...]

  • Page 8

    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 Specific Gravity Gas) Nominal Iron Pipe Size, Inches Internal Diameter, Inches Length of Pipe, Feet 10 32 72 132 278 520 1,050 1,600 3,050 4,800 8,500 17,500 20 22 49 92 190 350 730 1,100[...]

  • Page 9

    9 STEP 6: WIRING BOILER All electrical and control wir ing must be installed in accor- dance with the codes listed in Section 1 of this manual. F ol- low the wiring diagram f or your par ticular installation as shown in Figures 2.8, 2.9, 2.10, and 2.11. F or vent damper-equipped models , connect thermostat to blue leads (see Figures 2.4 & 2.4A)[...]

  • Page 10

    10 FIGURE 2.10: Wiring Diagram & Operation Sequence f or Boilers Equipped with Intermittent Pilot, V ent Damper and 400 Series or M & M PS804 L WCO FIGURE 2.11: Wiring Diagram & Operation Sequence f or Boilers Equipped with Standing Pilot, V ent Damper and 400 Series or M & M PS804 L WCO[...]

  • Page 11

    SECTION 3: ST AR T -UP & OPERA TION SEQUENCE OF OPERA TION F or sequence of operation of the par ticular boiler being installed, ref er to Figures 2.8, 2.9, 2.10 and 2.11 in Section 2 of this manual. Spill and rollout s witches are mounted on all GB200 boilers. The spill s witch detects the escape of combustion products through the draft div er[...]

  • Page 12

    12 Example: A GB200-4L boiler takes 5 min utes, 27 seconds to use 10 cubic f eet of natural gas. The local utility indicated the heating value of the natur al gas being supplied is 1000 Btu/cu ft. Theref ore: 5 minutes, 27 seconds = 327 seconds . 36,000 x 1000 = 110,000 Btu/hr 327 Theref ore, the boiler input is correct. NO TE: Before calculating t[...]

  • Page 13

    13 W ARNING: If you do not f ollow these instructions exactly , a fire or explosion ma y result with property damage, personal injury , or loss of life . LIGHTING CONTINUOUS PILO T INSTRUCTIONS Honeywell VR8200 Natural or Propane Gas A. BEFORE OPERA TING smell all around the appliance area f or gas. Be sure to smell ne xt to the floor because some [...]

  • Page 14

    14 T O TURN OFF APPLIANCE INLET GAS CONTROL KNOB SHOWN IN "OFF" POSITION GAS ON OFF INTERMITTENT PILO T - HONEYWELL VR8204 1. Set the thermostat to lowest setting. 2. T urn off all electr ic power to the appliance if service is to be perf or med. OPERA TING INSTRUCTIONS Intermittent Pilot - Honeywell VR8204 Natural or Propane Gas 1. ST OP[...]

  • Page 15

    15 4. Check gas manif old for proper position and reassemble burners to the manifold. Line up holes in b urners with the or i- fices, and slide assemb ly back into position. Be sure to rein- stall burner s with burner ports on the top surface (upright). 5. When a low w ater cut-off has been utilized, f ollow the manuf acturer ’ s maintenance inst[...]

  • Page 16

    1 Jac k et - Complete 59248 1 Jac k et - Complete 59249 1 1 Jac k et - Complete 59250 1 2 Bur ner - N.G./L.P . 59089 2334 3 Bur ner w/Pilot Brac ket - N.G./L.P . 59091 1111 4 Base Door Ass'y 59092 1 Base Door Ass'y 59093 1 1 Base Door Ass'y 59094 1 6 Base P an 59056 1 Base P an 59057 1 1 Base P an 59058 1 8 Manif old 59119 1 Manif ol[...]

  • Page 17

    Standing Pilot 5 Pilot Ass'y NG- Q314ALB, Q309A 72364 1 1 1 Pilot Ass'y NG- Q314ALB, Q309A 72365 1 Pilot Ass'y LP- Q314ALB, Q309A 72370 1111 Pilot Ass'y LP- Q314ALB, Q309D 72371 1 — Ther mocouple K16RA-30D 59109 1 1 1 Ther mocouple K16RA-36D 51006 1 9 Gas V alv e - NG VR8200H-1129 NG/LP* 59129 1111 28 T ransformer 115/24 V , 4[...]

  • Page 18

    18 27 13 12 11 16 17 26 8 5 3 10 4 6 30 14 9 2 15 32 33 20 25 22 23 24 21 FIGURE 1: GB200 GENERAL ASSEMBL Y 1 28 31 30 34[...]

  • Page 19

    19[...]

  • Page 20

    20 Any appliance that b urns natural gas, propane gas, fuel oil, wood or coal is capab le of producing carbon mono xide (CO). Carbon mono xide (CO) is a gas which is odorless, colorless and tasteless but is very toxic. If your Smith boiler is not w orking proper ly , or is not vented properly , dangerous levels of CO ma y accumulate. CO is lighter [...]