Smith Cast Iron Boilers GB300 manual

WESTCAST, INC. 260 NORTH ELM STREET WESTFIELD, MA 01085 TEL. (413) 562-9631 FAX (413) 562-3799 www.smithboiler.com GB300-IOM-4 GB300 NA TURAL OR PR OP ANE GAS BOILER INST ALLA TION & OPERA TING MANU AL Designed and tested accor ding to A.S.M.E. Boiler and Pressure V essel Code, Section IV for a maxim um allowab le working pressure of 80 psi US,[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 2 CONTENTS Getting Star ted ................................................... page 2 Boiler Ratings & Capacities ................................ page 3 Boiler Location ................................................... page 3 Combustion Air & V entilation ....................[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 3 Figure 1 Concrete Block Base Construction BOILER RA TINGS & CAP A CITIES Bef ore under taking the installation of the GB300(S,W) boiler check the boiler r ating plate to ensure that the boiler has been sized properly f or the job. The rating label has been pack ed with the controls[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 4 Each opening must ha ve a minimum free area of 1 in 2 /1000 Btu/hr , 2200 mm2/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 2 , 64,516 mm 2 in size . The upper opening must be within 12 in , 300 mm of [...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 5 CHIMNEY & VENT PIPE CONNECTIONS W ARNING: The vent installation must be in accordance with P art 7, V enting of Equipment, of the National Fuel Gas Code, ANSI Z223.1/NFP A54- latest revision or applicab le provisions of the local building codes. Canadian installa-tions must compl y[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 6 c . Where it is practical, close all b uilding doors and windows and all doors betw een the space in which the appliances remaining connected to the common v enting system are located and other spaces of the building. T urn on clothes dr yers and any appliance not connected to the comm[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 7 Figure 2A V er tical V enting Using A Metal Chimney System And Inside Air(GB300 Series) e . T est f or spillage at the draft hood relief opening after 5 minutes of main b ur ner operation. Use the flame of a match or candle, or smok e from a cigarette, cigar or pipe. F aire fonctionner[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 8 Figure 2C V ertical V enting Using A Masonry Chimney And Inside Air (GB300 Series) Figure 2B Dual Flue Outlets And Inside Air (GB300 Series) 5 FT 4.5 m 3 FT 0.9 m 2 FT 0.6 m 10 FT 3.4 m 10 FT 3.1 m 3 FT 0.9 m 3 FT 0.9 m[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 9 Figure 2E Common V ents And Inside Air (GB300 Series) Figure 2D Dual Flue Outlets Using A Masonry Chimney And Inside Air (GB300 Series) 10 FT 3.1 m 3 FT 0.9 m 3 FT 0.9 m 3 FT 0.9 m 10 FT 3.1 m 3 FT 0.9 m[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 10 Figure 2G Horizontal Venting And Inside Air (GB300) Figure 2F Dual Flue Outlets With T wo Boilers Using A Masonry Chimney And Inside Air (GB300 Series) 3 FT 0.9 m 10 FT 3.1 m 3 FT 0.9 m PITCH PIPE DOWN TOWA RDS TERMIN AL CAP 1/4 IN. PER F OOT 20MM/M OF RUN TO ALLOW FOR CONDEN SATE DRA[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 11 BOILER ASSEMBL Y Locate the boiler installation site based on the guidelines set f or th in the pre vious pages. A full concrete block f oundation is recommended to protect the boiler from moisture and debris. Use solid bloc ks to suppor t the boiler and hollow b locks f or the rest, [...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 12 Burner Base Assembly 5 thr ough 12 Sections Loosely attach the base baffle to the side panels using 4 5/16 stainless steel nuts . Install the burner base front, side and rear panels as shown in Figures 6, 7, 8 and 9A . Use a spirit lev el to ensure that the burner base panels are plum[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 13 Burner Base Assembly 13 thr ough 21 Sections Box 72694, X7 Splice Channels , contains the burner base front, intermediate and rear channels and additional 5/16" nuts and bolts , Figure 10 . Figure 10 X7 Bo x 72694 The base baffles must be attached to the intermediate base channel[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 14 Bolt the front and rear base panels in place, Figure 13 . Center the f actor y installed refractor y retention brack ets on the rear base panel so that the brac ket is in the middle of each refractory board Figure 13B . Figure 13A Burner Base, Side Front and Rear 13 to 21 Sections P a[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 15 Figure 18 Manifold Attac hments Locate the Bur ner Bo x. It is marked with a number from 72724 to 72731. Install three b ur ner tubes in the base, one on each end and one in the middle. Slide the closed end of the burner tube through the slot in the burner base rear panel. The notch i[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 16 Bolt the insulation splice panel brac ket to the front base channel, Figure 21 . Install the two insulation boards in the spaces between the two front and tw o rear burner base panels. Fir mly but carefully press the insulation boards in place and inser t the nails through the top and[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 17 Figure 25 Ceramic Blanket Placement Cast Iron Section Assemb ly W ARNING: Ne ver stand the cast iron sections up without adequate support. The y may fall o ver resulting in property damage or severe per sonal injury! Clean and inspect each section bef ore assembly . Use a wire brush a[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 18 Figure 26B Marking Burner Base Rear Midpoint Apply two coats of the spra y adhesive supplied with the boiler to the rope seal groo ves, Figure 27 . Allow time for the first coat to become tacky bef ore applying the second coat. CA UTION: Do not get any of the spray adhesive in the sea[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 19 T o ensure that the assemb led sections will be centered on the burner base the cast iron sections should be assembled from the midpoint of the b ur ner base outward. On boilers having an e ven number of sections the first inter mediate section should be placed so it’ s side surface[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 20 Figure 36 Lower P or t Seal Placement Figure 37 Upper P or t Seal Placement FCB & JSB FCB & JSB FCB & JSB FCB & JSB FCB & JSB FCB & JSB FCB & JSB FCB & JSB FCB & JSB Boiler Section Numbered from Left to Right Model 123456789 1 0 1 1 1 2 1 3 1 4 1 5 [...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 21 Make sure that the sections are square with the b ur ner base. Align the bottom front edge of the sections so they’ re flush with the face of the b ur ner base front panel, Figure 39 . Lift the next section into place being careful not to damage the ceramic b lanket or h ydronic sea[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 22 Figure 43 “J” Bolt Installation CAST IRON PRESSURE TEST NO TE: Before filling the sections with water temporarily set the flue collector(s) on top of the sections to locate the flue collector brac kets, Figure 44. On 13 to 21 section models attach the top jac ket splice panel brac[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 23 NO TE: All assembled boiler sections shall pass the hydr ostatic tests prescribed in Section IV of the ASME Boiler and Pressure V essel Code . CA UTION: Do not connect any boiler contr ols during the pressure test or they will be dama g ed! Completed boiler bloc ks must be tested as f[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 24 P osition the flue collector(s) on the boiler sections with the draft hood opening(s) at the rear of the boiler . The sides of the flue collector(s) should lie along the center of each end section, Figure 48 . Attach the flue collector(s) to the flue collector mounting brac kets using[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 25 Clean Out Cover s The clean out cov ers and mounting hardware are packaged in the Burner Bo x with a number from 72724 to 72731 on it, Figure 52 Figure 52 Clean Out Co ver & Hardware . Arrange the clean out co ver(s) in front of the boiler so the mounting stud locations can be det[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 26 MANIFOLD , BURNER AND PILO T INST ALLA TION Bo x 63273, Base P anel Sides , contains the manif old brac kets. Bolt the left and right manifold br ackets to the front burner base side panel flanges, Figures 16 and 57 . Figure 57 Manifold Brac ket Attachment Place the manif old on the b[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 27 Install the supplied 1/8" stainless steel bleed line on continuous pilot boilers equipped with V88A gas valv es. The bleed line m ust be located in a fixed position relativ e to the pilot burner and allowing f or the escaping gases to be readily ignited by the pilot. Use the supp[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 28 NO TE: Before installing the jac ket, an y nipples, steam risers or short pieces of pipe that will penetrate the jacket should be installed in the cast ir on sections. Do not attach an y fittings or other devices that would prevent the jac ket panels from fitting o ver them. NO TE: Th[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 29 The jack et should be assembled using the b lack screws provided. On 5 through 12 section models slide the rear panel behind the draft hood flanges with the grill side on the floor , Figures 68, 69 & 70 . On 13 to 21 section boilers open Bo x 55185, Jack et Splice Bo x, Figure 71 [...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 30 Remov e the left and r ight jac ket side panels from Bo x 55175, Jacket Side P anels . Remov e the knock outs necessar y to attach the water or steam piping and controls. NO TE: All jacket panel joints must be made so the panels are metal to metal. The insulation on the edges of the f[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 31 Figure 78 Rear T op Jacket P anel, 5 through 12 Figure 79 Rear T op Jacket P anel, 13 through 21 Install the front jack et top panel(s), Figures 80 and 81 . Figures 80 Front T op Jacket P anel, 5 through 12 Figure 81 Front T op Jacket P anel, 13 through 21 Bend the top panel(s) down a[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 32 On 13-21 section models a splice kit is required to assemble the front jac ket panels . The splice kit is shown in Figure 71 . The splice panel sits on the splice panel brac kets shown in Figure 45 and Figure 83 . Figure 84 shows the upper front splice panel in place . The panels sits[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 33 Install the front access panels as shown in Figure 86 5-12 sect and Figure 87 13-21 section using the supplied screws . Figure 86 Fr ont Access Panel 5 - 12 Sect Figure 87 Front Access P anel 13 - 21 Sect Attach the front grill side panels to the grill top panels as shown in Figure 88[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 34 Gas T rain Assemblies All threaded gas train connections m ust be made using a pipe compound that is resistant to the actions of liquefied petroleum gases. Pipe connections should be secure and tested f or leaks. This boiler is designed to allow f or the installation of the gas train [...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 35 HEA TING SYSTEM PIPING NO TE: The boiler jacket must be installed bef ore connecting the heating system piping and controls. All heating system piping must be installed b y a qualified technician in accordance with the latest re vision of the ANSI/ASME Boiler and Pressure V essel Code[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 36 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 valv es must be used to pre vent the chilled water from entering the boiler . When a boiler is[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 37 Figure 97 W ater Boilers in Battery Figure 97A T ypical Single Boiler Steam Piping Expansion Tank Pressure Reducing Valve Hi Limit Control ASME Safety Valve Temperature Pressure Gage Expansion Tank ASME Safety Valve External Low-water Cutoff Blowoff Valves Stop Valve Check Valve Check[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 38 Figure 98 T ypical Steam Piping - Gravity Return for Multiple Boiler s Figure 98A T ypical Steam Piping - Pumped Return for Multiple Boilers Stop Valve To Return Header ASME Safety Valve Stop Valve Stop Valve ASME Safety Valve Stop Valve Check Valve Check Valve Blowoff Valves LWCO &am[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 39 T able 6 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 maxim um possible demand. Do not neglect the pressure drop due to pipe fittings. T able 6 should be u[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 40 ELECTRICAL WIRING Electrical P ower Connections CA UTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and danger ous operation! V erify proper operation after servicing. The electrical connections to this boiler must be made in acco[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 41 BOILER OPERA TION W ARNING: Bef ore proceeding read and full y understand the instructions contained in this manual. Do not attempt to operate this boiler if it has not been installed in accor dance with the guidelines set f or th in this manual. Failure to comply with this warning ca[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 42 LIGHTING INSTR UCTIONS A . If this appliance is equipped with a continuous pilot it must be lit b y hand. Follo w the lighting instructions e xactly when lighting the pilot. If this appliance is equipped with an intermittent pilot, the ignition control will automatically light the pil[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 43 6 . Remov e the front gr ill(s). 7 . Connect a manometer having a minimum capacity of 20" WC to the outlet pressure por t of the gas valv e. Make sure that the gas supply piping has been purged of air and that all gas joints up to the gas v alve ha ve been thoroughly check ed for[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 44 1 . Attach a 20" manometer to the tap on the manifold. 2 . Remov e the regulator adjustment screw cap from the gas regulator . On systems that do not use a separate gas regulator , remov e the adjustment screw cap from the gas v alve body on the v alve closest to the gas supply p[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 45 Burner Installation 1 . DO NOT install damaged or badly corroded b ur ners, replace them. 2 . Install the burners by sliding the rear of the b ur ner tube into the slot located in the base rear panel. Slide the burner into the slot far enough so that the b urner brac ket clears the or[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 46 3 9 38 54 40 42 46 45 44 6 10 27 14 1 3 41 15 3 7 29 12 6 59 55 2 8 4 8 49 50 52 5 3 5 8 56[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 47 — Jac ket Less Sides P anels 55177 1 55178 1 2 1 55179 1 1 2 1 55180 1 1 2 1 55181 1 1 2 1 55182 1 1 2 55183 1 55184 1 — Jac ket Side P anels, Left & Right 55176 1 1 1 11111111111111 — Jac ket Splice P anels, F ront, T op, 55185 111111111 Rear & Grill — Jack et Screws [...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 48 12 Manifold Less Orifices 63243 1 63244 1 63245 1 63246 1 63247 1 63248 1 63249 1 63250 1 63253 1 63254 1 63255 1 63256 1 63257 1 63258 1 63259 1 63260 1 63261 1 13 Orifices, Natural Gas 60093 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 Orifices, LP Gas 60242 8 10 12 14 16 18 20[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 49 — Manual Main Shut Off V alve, 1" 62023 1 1 1 1 1 1 Manual Main Shut Off V alve, 1-1/4" 62024 1111111111 Manual Main Shut Off V alve, 1-1/2" 62025 1 — Manual Pilot Shut Off V alve, 62028 1 1 1 11111222222222 — Pilot Regulator R V12L T 50961 1 1 1 11111111111111 ?[...]

GB300 BOILER INST ALLA TION AND OPERA TION INSTR UCTIONS Page 50 41 Cast Iron Section, Left Side 3651 1 1 1 11111111111111 42 Gasket, Upper P or t 60248 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Gasket, Lo wer P or t 60249 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 — 3/8" Rope, 42" length 71601 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1[...]

dizziness headaches nausea vision problems loss of muscle control weakness shortness of breath unclear thinking unconsciousness Page 51 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 [...]

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