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Smith Cast Iron Boilers GB250 SERIES, Installation & Operation Manual

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Smith Cast Iron Boilers GB250 SERIES Installation & Operation Manual Download Page 1

GB250-IM-5

42-9185

GB250 SERIES 

INSTALLATION, OPERATION 

& MAINTENANCE MANUAL 

AND REPLACEMENT PARTS LIST

Gas-Fired Steam Cast Iron Boilers 

175,000 to 400,000 Btuh Input

Standing Pilot, Standing Pilot & Vent Damper,

Intermittent Pilot, Intermittent Pilot & Vent

Damper

SECTION 1: INTRODUCTION
Code Compliance. ....................................................2
Venting Requirements ..............................................3
Chimney Requirements ............................................3
Combustion Air Requirements ..................................3
Water Treatment........................................................4
Shipment of Boiler ....................................................4

SECTION 2: BOILER INSTALLATION
Step 1: Locating/Setting Boiler..................................5
Step 2: Installing Steam Piping ................................6
Step 3: Installing Hydronic Components ..................7
Step 4: Venting Boiler................................................7
Step 5: Installing/Testing Gas Piping ......................10

Step 6: Wiring Boiler ..............................................11

SECTION 3: START-UP & OPERATION
Sequence Of Operation ..........................................16
Prior To Start-Up ....................................................16
Start-Up & Adjustments ..........................................16

SECTION 4: MAINTENANCE
Before Each Heating Season..................................19
How To Change Orifices ........................................20
Heating System Problems & Causes ......................20
Replacement Parts List ..........................................21
Warnings ................................................................25

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

Summary of Contents for GB250 SERIES

Page 1: ...pment of Boiler 4 SECTION 2 BOILER INSTALLATION Step 1 Locating Setting Boiler 5 Step 2 Installing Steam Piping 6 Step 3 Installing Hydronic Components 7 Step 4 Venting Boiler 7 Step 5 Installing Testing Gas Piping 10 Step 6 Wiring Boiler 11 SECTION 3 START UP OPERATION Sequence Of Operation 16 Prior To Start Up 16 Start Up Adjustments 16 SECTION 4 MAINTENANCE Before Each Heating Season 19 How To ...

Page 2: ... local codes 2 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 CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor injury or pr...

Page 3: ...utlined 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 approac...

Page 4: ...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...

Page 5: ...s are proper as shown Local requirements may specify greater clearances must be adhered to Boiler shall be install ed such that the gas ignition system com ponents are protected from water dripping spraying rain etc during appliance oper ation and service WARNING Never install boiler on combustible flooring without combustible flooring pan or on carpeting as heat damage and or fire may result FIGU...

Page 6: ...ing 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 Proper steam piping practices must be followed at all times Maint...

Page 7: ... 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...

Page 8: ...t 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 ca...

Page 9: ...t 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...

Page 10: ...0 990 1 600 2 800 5 800 90 10 22 40 84 160 320 490 930 1 500 2 600 5 400 100 9 21 38 79 150 305 460 870 1 400 2 500 5 100 125 8 18 34 72 130 275 410 780 1 250 2 200 4 500 150 8 17 31 64 120 250 380 710 1 130 2 000 4 100 175 7 15 28 59 110 225 350 650 1 050 1 850 3 800 200 6 14 26 55 100 210 320 610 980 1 700 3 500 1 4 3 8 1 2 3 4 1 1 1 4 1 1 2 2 2 1 2 3 4 326 493 622 824 1 049 1 380 1 610 2 067 2 ...

Page 11: ... 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 power to the gas valve in case the primary press...

Page 12: ...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 FIGURE 2 13 WIRING DIAGRAM OPERATION SEQUENCE FOR BOILERS WITH STANDING PILOT MCDONNELL MILLER 67 LOW WATER CUT OFF EXCEPT GB250 8 GB250 9 N G FIGURE 2 14 WIRING DIAGRAM OPERATION SEQUENCE FOR BOILERS EQUIPPED WITH STANDING PILOT MCDONNELL MILLE...

Page 13: ...ILERS EQUIPPED WITH INTERMITTENT PILOT VENT DAMPER MCDONNELL MILLER 67 LOW WATER CUT OFF FIGURE 2 14 WIRING DIAGRAM OPERATION SEQUENCE FOR BOILERS EQUIPPED WITH STANDING PILOT VENT DAMPER MCDONNELL MILLER 67 LOW WATER CUT OFF EXCEPT FOR GB250 8 GB250 9 N G ...

Page 14: ...SEQUENCE FOR BOILERS EQUIPPED WITH STANDING PILOT VENT DAMPER MCDONNELL MILLER 67 LOW WATER CUT OFF FOR GB250 8 GB250 9 N G FIGURE 2 16 WIRING DIAGRAM OPERATION SEQUENCE FOR BOILERS EQUIPPED WITH INTERMITTENT PILOT VENT DAMPER 400 SERIES LWCO ...

Page 15: ...ATION SEQUENCE FOR BOILERS EQUIPPED WITH STANDING PILOT VENT DAMPER 400 SERIES LWCO EXCEPT FOR GB 250 8 9 FIGURE 2 18 WIRING DIAGRAM OPERATION SEQUENCE FOR BOILERS EQUIPPED WITH STANDING PILOT VENT DAMPER 400 SERIES LWCO GB250 8 9 ONLY ...

Page 16: ...er sits SYSTEM START UP 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 Z21 13 1 Check combination gas valve on boiler and make sure it is in the OFF position 2 For vent damper equipped models with the thermostat set to call for heat observe that vent damper positio...

Page 17: ...essures If 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 Canada Occasionally however local gas characteristics may not allow unit to be properly adjusted for...

Page 18: ...nclosing 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 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 button and it will pop back up Pilot should r...

Page 19: ...ON THE TOP SURFACE UPRIGHT 5 When a 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 Adjust...

Page 20: ...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 HEATING SYSTEM PROBLEMS CAUSES No Heat 1 Blown fuse or circuit breaker 2 Switch turned off 3 Pilot outage 4 IID system malfunction 5 F...

Page 21: ...ld 63276 1 1 Manifold 59123 1 Manifold 63278 1 Manifold 59125 1 Manifold 59126 1 11 Burner Orifice No 31 N G 59141 6 Burner Orifice No 32 N G 59142 5 9 10 Burner Orifice No 33 N G 59143 8 Burner Orifice No 34 N G 59144 5 Burner Orifice No 52 L P 59150 5 5 6 8 9 10 MODEL GB250 SERIES REPLACEMENT PARTS LIST ORDERING INFORMATION When ordering replacement parts provide the model and serial number show...

Page 22: ...Hood 8 For Spill Switch 59217 1 Draft Hood 8 59218 1 Draft Hood 9 59219 1 1 31 Junction Box 4 x 4 60178 1 1 1 1 1 1 Silicone Sealant 11 oz 40440 3 8 Fiberglass Rope 5 Ft Block to Base Seal 60024 32 Vent Damper 7 w Harness Ass y 69496 1 1 Vent Damper 8 w Harness Ass y 69497 1 1 Vent Damper 9 w Harness Ass y 69498 1 1 Cable Bracket 59270 1 1 1 1 1 1 33 Manual Reset Spill Switch 59273 1 1 1 34 Manual...

Page 23: ...51B 1103 72360 1 1 Pilot Ass y L P Q3451B 1103 72361 1 N A N A Pilot Ass y L P Q3451B 1103 70008 1 10 Gas Valve N G VR8304P 4332 59136 1 1 1 1 1 1 Gas Valve L P VR8304P 3340 59137 1 1 1 Gas Valve L P VR8304P 4330 59138 1 1 1 Ignition Control S8600M 1013 51177 1 1 1 1 1 1 Ignition Cable 36 Lg 59308 1 1 1 1 1 1 30 Transformer 120 24 1006 43VA 50172 1 1 1 1 1 1 23 REF GB250 GB250 GB250 GB250 GB250 GB...

Page 24: ...24 29 33 17 15 14 13 18 19 25 27 10 6 7 4 3 11 31 30 5 2 28 32 1 JACKET ASSEMBLY 34 16 26 9 23 24 22 ...

Page 25: ...ce 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...

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Page 28: ...WESTCAST INC 260 NORTH ELM STREET WESTFIELD MA 01085 TEL 413 562 9631 FAX 413 562 3799 www smithboiler com ...

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