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Smith Cast Iron Boilers Series 28A manual

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Table of contents for the manual

  • Page 1

    SERIES 28A GAS OR OIL BOILER INST ALLA TION & OPERA TING INSTR UCTIONS WESTCAST , INC. 260 NORTH ELM STREET WESTFIELD, MA 01085 TEL. (413) 562-9631 F AX (413) 562-3799 DESIGNED AND TESTED A CCORDING T O A.S.M.E. BOILER AND PRESSURE VESSEL CODE, SECTION IV FOR A MAXIMUM ALLO W ABLE WORKING PRESSURE OF: 15 PSI STEAM OR 80 PSI W A TER. W ARNING: I[...]

  • Page 2

    Page 2 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS CONTENTS Bef ore Y ou Star t ................................................. page 2 Boiler Ratings & Capacities ................................ page 2 Boiler Location ................................................... page 2 Combustion Air & V entilation ..............[...]

  • Page 3

    Page 3 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Figure 1- Service Clearances to Adjacent Construction W ARNING: Never install a 28A boiler on top of combustib le flooring without consulting the local building authorities f or proper installation guidelines! A minimum c learance of 6 in, 0.15 m must be maintained between the boi[...]

  • Page 4

    Page 4 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS All Air From Inside The Building If the boiler is to be located in a confined space mini- mum clearances of 24 in , 610 mm must be maintained between the boiler and any adjacent construction. When installed in a confined space, two permanent openings communicating with an addition[...]

  • Page 5

    Page 5 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Chimney Inspection & Sizing If this boiler will be connected to a masonr y chimney , a thorough inspection of the chimney m ust be perf or med. Ensure that the chimney is clean, properly constructed, lined and properly sized, see Figure 2. T able 2 lists the equiv alent breech[...]

  • Page 6

    Page 6 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS W ARNING: Failure to maintain minimum clearances between vent connector s and any combustib le material can result in a fire causing extensive pr operty damage, se vere per sonal injury or death! COMMON VENT SYSTEMS If an e xisting boiler is remov ed from a common venting system, [...]

  • Page 7

    Page 7 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS c) Insof ar as is practical, close all b uilding doors and windows and all doors between the space in which the appliances remaining connected to the common v enting system are located and other spaces of the building. T ur n on clothes dr y ers and any appliance not connected to [...]

  • Page 8

    Page 8 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Completed boilers must be tested as f ollo ws: Steam Boilers – the assembled boiler sections shall be subjected to a h ydrostatic test pressure of not less than 45 psig , 315 kP a . W ater Boilers – the assembled boiler sections shall be subjected to a h ydrostatic test pressu[...]

  • Page 9

    Page 9 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS 5 . Inser t the large por t connector with its steel inner ring into the upper por t. 6 . Inser t the two round por t connectors into the lower por ts. NO TE: Appl y the spra y adhesive supplied with the boiler to the port recess to hold the por t connector in place if necessary .[...]

  • Page 10

    Page 10 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS 9 . Assemble the rest of the sections f ollowing steps 3 through 8 abov e. 1 0 . Hydrostatically test the boiler by f ollowing the instructions on page 8. 11. While the boiler is being filled confirm that all of the draw r ods are properly tor qued and that there are no leaks. 1 [...]

  • Page 11

    Page 11 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Figure 8 - Burner Mounting Plate Details Figure 9 - Observation P ort Assembly Observation P or t Assembl y , Figure 9 1 . P osition the hinged end of the steel flapper door , # 5, ov er the boss on the obser v ation por t cover , # 4. 2 . Drive the e xpansion pin, # 7, through t[...]

  • Page 12

    Page 12 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Observation P or t Installation 1 . Screw the f our 5/16-18 x 1 1/2 studs into the tapped holes around the obser v ation cover opening in the back section. 2 . Place the obser vation por t cov er assembly ov er the studs and install the washers and nuts . Tighten the nuts unif or[...]

  • Page 13

    Page 13 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS T ankless Heater Installation - Optional 1 . Clean the heater flange to remov e any rust or debris. 2 . Install the f our 7/16" x 1 1/2" studs into the tapped holes in the tankless heater flange on the section, Figure 11. Figure 11 - T ankless Heater Installation 3 . Pl[...]

  • Page 14

    Page 14 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS GENERAL PIPING REQUIREMENTS CA UTION: Never use automotive antifreeze in the boiler or heating system. If antifreeze is necessar y it must be f ormulated specifically f or hydronic heating systems, such as ethylene or pr opylene glycol. Failure to compl y with this caution will v[...]

  • Page 15

    Page 15 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Figure 15 - Relief & Safel y V alve Piping W A TER BOILER PIPING The supply and retur n connections should be sized to suit the system, see Figures 13, 14, 16, 17 and T ables 5 & 6. Do not pipe the supply from the bottom por t or the return to the top por t, the boiler wi[...]

  • Page 16

    Page 16 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Piping For Use With Cooling Units The boiler , when used in connection with a refr igeration system, must be installed so the chilled medium is piped in parallel with the boiler . Appropriate valves m ust be used to prev ent the chilled water from entering the boiler , see Figure[...]

  • Page 17

    Page 17 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Figure 18 - T ypical Single W ater Boiler Piping Figure 19 - T ypical Multiple Water Boiler Piping[...]

  • Page 18

    Page 18 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS NO TE: Some locations do not allo w this solution to be used. Check with the local authority having jurisdiction. 4 . Mix the cleaning chemicals with water to create a concentrated solution. P our the cleaning solution through one of the top tappings in the front section and plug[...]

  • Page 19

    Page 19 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Minimum F eed W ater Condensate Receiver Boiler I=B=R Gross Output Ev aporation Rate Pumping Rate Capacity Model MBH kW GPM L/hr GPM L/hr Gallons Liters 28A-S-4 900 264 1.9 7.3 3.9 14.8 37 140 28A-S-5 1166 342 2.5 9.5 5.0 18.9 48 182 28A-S-6 1433 420 3.1 11.7 6.2 23.5 59 223 28A-[...]

  • Page 20

    Page 20 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Figure 22 - T ypical Steam Piping - Gravity Return for Multiple Boiler s Figure 23 - T ypical Steam Piping - Pumped Return for Multiple Boiler s[...]

  • Page 21

    Page 21 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Install 3" nipples and ball valv es in the two 3" NPT front section tappings so the boiler can be blo wn down. The f eed water requirements f or steam boilers at full input are shown in T able 9. The addition of water to the boiler should be controlled by sensing the ac[...]

  • Page 22

    Page 22 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS W ater Boilers Fill the boiler and all of the radiation with water to the required system pressure. Completely purge the system of air and adjust the system pressure as needed. CA UTION: Thermal shock of water boiler s must be av oided! W ater circulation must be estab lished bef[...]

  • Page 23

    Page 23 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS BOILER CHECKING & ADJUSTMENT CA UTION: Never increase the input to the boiler above that f or which it is rated. Doing so can cause premature failure of the boiler! Low Water Cutoff Ensure that the low w ater cutoff de vice(s) function(s) properly . T est in accordance with t[...]

  • Page 24

    Page 24 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS 6 . V acuum out the bur ner base and clean and inspect all of the components. Replace any damaged or badly corroded par ts. 7 . Inspect the cleanout cov er insulation and rope seal. If damaged or deteriorated replace them. 8 . Install the clean out cov ers and reseal them with a [...]

  • Page 25

    Page 25 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Figure 25 - Boiler Assembl y[...]

  • Page 26

    Page 26 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS 1 F ront Section 3621 111111111111111 2 Graphite P or t Connector Set 60375 3456789 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 3 Draw Rod Washers 62099 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 4 5/8" x 11" Draw Rods 60102 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 5 Draw Rod[...]

  • Page 27

    Page 27 SERIES 28A BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS ns Rear Observation P or t Hardware 71301 1 11111111111111 Burner Mounting Plate Assembly , 9" 70641 Burner Mounting Plate Assembly , 10 1/4" 70640 34 (3) Burner Mounting Plate Assembly , 12 1/2" 70510 Burner mounting plate deter mined by burner selection Burner Mo[...]

  • Page 28

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