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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 Step 6: Wiring Boiler ..............................................11
Code Compliance. ....................................................2
Venting Requirements ..........................................
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SECTION 1: INTRODUCTION requirements of the authority having jurisdiction or, in CODE COMPLIANCE the absence of such requirements, with the National Boiler installations must conform to the requirements of Electrical Code, ANSI/NFPA No.70-latest edition. UL the authority having jurisdiction or, in the absence of listed power limited circuit cable is almost universally such requirements, to the National Fuel Gas Code ANSI approved for safety controls on heating equipment, Z223.1-latest edition.
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7. Any improper operation of the common venting sys- VENTING REQUIREMENTS tem should be corrected so the installation conforms When connecting to gas vents or chimneys, vent instal- with National Fuel Gas Code, ANSI Z223.1-latest lations shall be in accordance with Part 7, Venting of edition. When resizing any portion of the common Equipment, of the National Fuel Gas Code, ANSI venting system, the common venting system should be Z223.1-latest edition, or applicable provisions of the resized to a
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WARNING: Adequate fresh air must be provided for NOTE: Boiler utilizes synthetic rubber seals. Water combustion. Improper boiler operation and treatment chemicals and system cleaning chemicals inadequate venting of deadly flue gases may must be compatible with this and all other otherwise result. construction materials. NOTE: Boiler employs atmospheric combustion. SHIPMENT OF BOILER Combustion air must not be contaminated with Each boiler is shipped in a single carton. Draft hood is halogenated
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SECTION 2: BOILER INSTALLATION STEP 1: LOCATING AND SETTING THE BOILER ➤ PROCEDURE A: Check that provisions for combustion air are in accordance with National Fuel Gas Code ANSI Z223.1-latest edition and all applicable local codes. In Canada, follow CAN/CGA B149(.1 or .2) installation codes. FIGURE 2.1 ➤ PROCEDURE B: Check minimum 6" 6" clearances to combustibles are proper as shown. Local VENT DAMPER * TOP requirements may specify greater clearances & must be 1 1 1 1 1 1 1 adhered to. 1 1 11
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COLD WATER FILL RETURN ➤ PROCEDURE C: Check component positioning. 1. Remove all packing material from boiler. 2. Install on non-combustible floor only, unless local codes permit 6" OVERHANG OF BLOCK AND AA SHEETMETAL ALL AROUND use and fabrication of a fireproof base (see Fig. 2.2). AA 4" HOLLOW CLAY TILE (TWO COURSES) OPENINGS THRU 3. Check that burners and controls 22 GAUGE BLOCKS IN TOP COURSE TO AAAA SHEETMETAL are in the proper position. 0 BE AT 90 ANGLE TO OPENINGS 6" THRU BOTTOM COUR
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STEP 3: INSTALLING HYDRONIC COMPONENTS A low-water cutoff must be installed to protect the unit from dry-fire. PRESSURE Screw extension nipple into 3/4" tapping on top of the RELIEF VALVE absorption unit and install relief valve into top of nipple with the spindle in the vertical position (i.e., with the valve discharge in the horizontal)(See Figure 2.4). WARNING: No Valve of any type may be installed between the boiler and the relief valve to prevent accidental explosion from overpressure. Most
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The flue or vent connectors must be installed flush with Remove hairpin shipping clip which holds damper blade the inside chimney liner surface and sealed in place with in closed position and observe that damper blade furnace cement. Horizontal portions of the single wall rotates slowly to open position. Do not force it closed as and type B venting systems shall be supported by use it may damage the gear train and void the warranty. The of strap hangers or their equivalent. Vent supports blade s
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of the largest flue plus 50% of the areas of the additional flue ATTACH LOWER PORTION OF or vent connectors. VENT DAMPER TO DRAFTHOOD When an existing boiler is removed from a common venting OUTLET WITH 1/2" system, common venting system is likely to be too large for AAAAA OR SHORTER proper venting of appliances remaining connected to it. At time SCREWS OR AAAAA of removal of existing boiler, following steps shall be followed POP RIVETS with each appliance remaining connected to the common AAAAA
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STEP 5: INSTALLING & TESTING GAS PIPING Connect the gas piping from the meter to the boiler Install a full-sized sediment trap at the low point in gas using a pipe size which will result in a pressure drop of line upstream of gas valve. Install a non-restrictive less than 0.3" W.C. for natural gas or 0.5" W.C. for lubricated plug valve in the gas line close to the boiler. propane. See Figure 2.10 for the appropriate gas pipe Install a ground joint union at the gas valve inlet to allow sizing and
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Testing Gas Piping RISER TO OTHER BEAM APPLIANCES DANGER: Before placing gas piping into service, A carefully test it to assure every joint is gas tight. Bubble test all joints with a soap solution. NEVER PIPE CLAMP TEST WITH AN OPEN FLAME AS FIRE OR GAS MANUAL MAIN EXPLOSION WILL RESULT. METER SHUT OFF VALVE For any pressure testing in excess of 1/2 psi, the boiler and its individual shutoff valve must be isolated from the piping system by disconnecting them and capping the FIGURE 2.11 outle
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For vent damper-equipped models, connect thermostat NOTE: Boiler transformer must not be used to power external accessories (i.e., zone valves, to blue leads (see Figure 2.6). relays, etc.) Otherwise, transformer will be overloaded and burn out. NOTE: If any of original wire supplied with boiler must be replaced, use similar wire of 105° C rating. Otherwise, insulation may melt or degrade, exposing bare wire. FIGURE 2.13: WIRING DIAGRAM & OPERATION FIGURE 2.14: WIRING DIAGRAM & OPERATION SEQUE
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FIGURE 2.14: WIRING DIAGRAM & OPERATION FIGURE 2.13: WIRING DIAGRAM & OPERATION SEQUENCE FOR BOILERS EQUIPPED WITH SEQUENCE FOR BOILERS EQUIPPED WITH STANDING PILOT, VENT DAMPER & MCDONNELL- INTERMITTENT PILOT, VENT DAMPER & MILLER #67 LOW WATER CUT-OFF (EXCEPT FOR MCDONNELL-MILLER #67 LOW WATER CUT-OFF GB250-8 & GB250-9, N.G.) 13
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FIGURE 2.15: WIRING DIAGRAM & OPERATION FIGURE 2.16: WIRING DIAGRAM & OPERATION SEQUENCE FOR BOILERS EQUIPPED WITH SEQUENCE FOR BOILERS EQUIPPED WITH STANDING PILOT, VENT DAMPER & MCDONNELL- INTERMITTENT PILOT, VENT DAMPER & 400 MILLER #67 LOW WATER CUT-OFF (FOR GB250-8 & SERIES LWCO GB250-9, N.G.) 14
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FIGURE 2.17: WIRING DIAGRAM & OPERATION FIGURE 2.18: WIRING DIAGRAM & OPERATION SEQUENCE FOR BOILERS EQUIPPED WITH SEQUENCE FOR BOILERS EQUIPPED WITH STANDING PILOT, VENT DAMPER & 400 SERIES STANDING PILOT, VENT DAMPER & 400 SERIES LWCO (EXCEPT FOR GB-250-8 & 9) LWCO (GB250-8 & 9 ONLY) 15
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SECTION 3: START-UP & OPERATION SEQUENCE OF OPERATION PRIOR TO START-UP For sequence of operation of the particular boiler being Fill system with water until the water level indicator installed, refer to Figures 2.13 through 2.18 in Section 2 (sight glass) is approximately 2/3 full. This water level is of this manual. 23" from the surface on which the boiler sits. Spill and rollout switches are mounted on Model SYSTEM START-UP & ADJUSTMENTS GB250-5L, GB250-5H, and GB250-6 boilers. Safe lighting
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CAUTION: Never leave the job with yellow burning Canada. Occasionally, however, local gas flames. This condition indicated poor combustion characteristics may not allow unit to be properly and will quickly carbonize the boiler, reducing adjusted for input. If this is the case, local utility or efficiency and boiler life. It may also be an indication Smith may recommend orifices be changed. When of improper venting or combustion air supply. If changing orifices follow the procedures detaile
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WARNING: If you do not follow these instructions exactly, a fire or explosion may result with property damage, personal injury, or loss of life. A. BEFORE OPERATING smell all around the appliance B. Use only your hand to push in or turn the gas control area for gas. Be sure to smell next to the floor because some knob. Never use tools. If the knob will not push in or turn by gas is heavier than air and will settle on the floor. hand, don't try to repair it; call a qualified service technician.
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TO TURN OFF APPLIANCE 1. Set the thermostat to lowest setting. 2. Turn off all electric power to the appliance if service is to be performed. 3. Turn gas control knob counterclockwise to "OFF". Do not force. SECTION 4: MAINTENANCE This boiler has been designed to provide years of 3. Check and clean burner assembly. Remove burner trouble free performance in normal installations. access panel. Lift burners up and to rear until burners Examination by the homeowner at the beginning of each are d
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7. Continue this process for a minimum of one hour. HEATING SYSTEM PROBLEMS & CAUSES The process should continue until the steam is dry (no No Heat water coming from the vent when the water in the gauge 1. Blown fuse or circuit breaker. glass is at a normal level, approximately 2/3 full). The 2. Switch turned off. time required could vary up to 3 hours. 3. Pilot outage 4. IID system malfunction. 8. Turn burner to off position. While boiler is still hot, 5. Flue damper not open. drain completely
