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GTIOM-3
MODEL GT SERIES
INSTALLATION, OPERATING
AND MAINTENANCE MANUAL
Modulating, Direct Vent, Gas-Fired Condensing Boilers
Natural Or Propane
150,000 to 399,000 Btuh Input
ENERGY ST ENERGY STAR AR
gama
see note
WARNING: If the information in this manual is not followed exactly, a fi re or explosion
may result causing property damage, personal injury or loss of life.
Do not store or use gasoline or other fl ammable vapors and liquids in the vicinity of
this or any other appliance.
WHAT TO DO
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Page 2 GT INSTALLATION AND OPERATION INSTRUCTIONS To obtain the safe, dependable, efficient operation CONTENTS and long life for which this boiler was designed, these Before You Start ................................................. page 2 instructions must be read, understood and followed. Boiler Ratings & Capacities ...............................page 2 Boiler Location ...................................................page 3 Direct all questions to your Smith distributor or to the Clear
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GT INSTALLATION AND OPERATION INSTRUCTIONS Page 3 Figure 1- Input vs Elevation Graph 400 300 200 100 0 0-2000 3000 4000 5000 6000 7000 8000 9000 10000 Elevation (ft) GT-150 GT-200 GT-400 WARNING: At elevations greater than 2000 ft, 2. An optimum site will be level, central to the hot water 660 m, the combustion of the GT must be checked piping system and close to an outside wall. with a calibrated combustion analyzer to ensure safe and reliable operation. Consult the Operating NOTE: This boil
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Page 4 GT INSTALLATION AND OPERATION INSTRUCTIONS Table 1 - Clearances One of the following materials is to be used for the air intake pipe: Combustible Service • GT-150 & 200: 3 in, 76 mm, PVC Sch.40 pipe or Clearance Clearance Galvanized Steel pipe. Surface in mm in mm • GT-400: 4 in, 102 mm or 6 in 152 mm, PVC Sch.40 Front 0 0 24 610 pipe or Galvanized Steel pipe. Back 0 0 0 0 Sides 0 0 12 305 See Table 2 for the maximum equivalent air intake Top 0 0 12 305 system leng
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GT INSTALLATION AND OPERATION INSTRUCTIONS Page 5 The GT condensing gas boiler is a high efficiency Table 2 - Vent & Air Intake System Sizing boiler utilizing induced power venting. It is designed to be vented directly to the outdoors using the venting Model Equivalent Combined Vent & Air Intake methods and materials detailed in this section. The Number System Length (see note) vent system must be both gas tight and watertight. All GT-150 105 ft, 32 m horizontal vent piping must be sloped ba
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Page 6 GT INSTALLATION AND OPERATION INSTRUCTIONS The vent terminal shall not terminate: Consult your weather office for the maximum typical • Directly above a paved sidewalk or a paved drive-way snowfall for your region. For example, in Boston MA the that is located between two buildings, and that serves maximum typical snowfall is 12 in, 305 mm. Therefore both buildings; the inlet must be 24 in, 610 mm, above any surface • Less than 7 ft, 2.1 m above grade where located that will support
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GT INSTALLATION AND OPERATION INSTRUCTIONS Page 7 When penetrating an outside wall the air intake and vent For installations that have to exit the foundation below pipes must be constrained as shown in Figure 6. The grade excavate the site as shown in Figure 8 to a point openings through which the air intake and vent pipes below where the pipes exit the building. Maintain the pass must be properly sealed to prevent products of proper vent clearances as outlined above. Attach the vent combust
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Page 8 GT INSTALLATION AND OPERATION INSTRUCTIONS Figure 9 - External Air Intake and Vent Systems Figure 11- Horizontal Concentric Terminal Location SUPPORTS EVERY 24 IN EXHAUST 20 FOOT MAX OUTSIDE USING ONLY 3" PIPE ON THE 150 & 200 AND 4" PIPE ON THE 400 INLET 12 IN ABOVE MAXIMUM SNOW LINE The debris screens provided with the boiler must be installed in both the air intake and vent terminals. Install the screens in the outer most opening then glue a 1 in, 25 mm length of pipe into the openi
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GT INSTALLATION AND OPERATION INSTRUCTIONS Page 9 Figure 13 - Wall Penetration Detail Consult your weather office for the maximum typical snowfall for your region. For example, in Boston MA the maximum typical snowfall is 12 in, 305 mm. Therefore the inlet must be 24 in, 610 mm, above any surface that will support snow. The exhaust must be 42 in, 1067 mm, above this surface. Figure 15 - Two Pipe Through the Roof The debris screen provided with the boiler must be installed in the concentric
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Page 10 GT INSTALLATION AND OPERATION INSTRUCTIONS Install and seal a rain cap over the dormant chimney Figure 18 - Multiple Concentric Through the Roof opening to prevent water from entering the building. sch.40 Use only ABS, PVC , CPVC, or AL294C pipe for the air inlet and vent systems as stated previously. Ensure that the air inlet and vent system lengths are within the maximums specifi ed in Table 2. The debris screens provided with the boiler must be installed in both the air intake and
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GT INSTALLATION AND OPERATION INSTRUCTIONS Page 11 The following are important rules that must be followed CAUTION: All systems must be fl ushed to remove when constructing the condensate system: sediment, flux, filings and other foreign matter. 1. Connect the condensate trap to the drain using Use products such as Fernox “Superfl oc” for new 1/2 in, 13 mm, silicone, rubber, reinforced nylon, or installations and CHR “Central Heating Restorer” PEX tubing. Long runs must be properly pitched fo
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Page 12 GT INSTALLATION AND OPERATION INSTRUCTIONS Understand and follow the plumbing requirements Pressure Relief Valve provided in this section. Keep serviceability in mind Each boiler is equipped with a 30 psi pressure relief when installing plumbing around the boiler cabinetry. valve that must be piped in accordance with the ANSI/ Install fi ttings that will allow the system to be fl ushed if ASME Boiler and Pressure Vessel Code, Section IV to needed during annual check-ups. Add an inhibitor
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GT INSTALLATION AND OPERATION INSTRUCTIONS Page 13 Low Water Cut Off, LWCO Figure 22 - Boiler Head Loss If a LWCO is used ensure that the water line of the “Low GT-150 GT-200 GT-400 Water Cutoff” is at least 6 in, 152 mm, above the top of the boiler, Figure 21. It is recommended that the LWCO be 60 situated so that it can be tested without removing water from the boiler. Tri-cocks and a gauge glass are highly 40 recommended. Valves shall not be installed between the LWCO and the boiler. Us
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Page 14 GT INSTALLATION AND OPERATION INSTRUCTIONS Figure 23 - Single Boiler with Indirect Hot Water Heater NOTES: 1. All piping and pumps must be supported so that no loads or stresses are applied to boiler heat exchanger. To make boiler service easy use Unions or fl exible Vibration Isolation Kit. 2. This boiler is provided with a 1/8" vent that is not intended for continuous system venting. 3. For continuous system venting use a cast iron air scoop, for excessive air conditions use a Sp
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GT INSTALLATION AND OPERATION INSTRUCTIONS Page 15 Figure 24 - Multiple Boiler Installation NOTES: 1. All piping and pumps must be supported so that no loads or stresses are applied to boiler heat exchanger. To make boiler service easy use Unions or fl exible Vibration Isolation Kit. 2. This boiler is provided with a 1/8" vent that is not intended for continuous system venting. 3. For continuous system venting use a cast iron air scoop, for excessive air conditions use a Spirovent. Do not
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Page 16 GT INSTALLATION AND OPERATION INSTRUCTIONS Figure 25 - Multiple Zones Using Circulators NOTES: 1. All piping and pumps must be supported so that no loads or stresses are applied to boiler heat exchanger. To make boiler service easy use Unions or fl exible Vibration Isolation Kit. 2. This boiler is provided with a 1/8" vent that is not intended for continuous system venting. 3. For continuous system venting use a cast iron air scoop, for excessive air conditions use a Spirovent. Do
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GT INSTALLATION AND OPERATION INSTRUCTIONS Page 17 Figure 26 - Multiple Zones Valves with Bypass Valve Note: Velocity noise may be a problem when the entire output of the system pump is fl owing through the zone with the highest pressure drop. Adjust the differential bypass valve to eliminate noise. NOTES: 1. All piping and pumps must be supported so that no loads or stresses are applied to boiler heat exchanger. To make boiler service easy use Unions or fl exible Vibration Isolation Kit.
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Page 18 GT INSTALLATION AND OPERATION INSTRUCTIONS Safe lighting and other performance criteria were met GAS SUPPLY PIPING with the gas manifold and control assembly provided on The GT hot water boiler comes from the factory ready the boiler when the boiler underwent tests specifi ed in to be piped to the gas supply. The National Fuel Gas ANSI Z21.13/CSA 4.9. All gas connections MUST be leak Code, ANSI Z223.1/NFPA 54 and local codes for gas tested before putting the boiler into operation.
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GT INSTALLATION AND OPERATION INSTRUCTIONS Page 19 Before supplying 120 volts to the boiler, do a continuity ELECTRICAL WIRING check between all the wires and the ground to make sure that there are no electrical shorts that could damage the CAUTION: Label all wires prior to disconnection Sentry 2100 board. when servicing controls. Wiring errors can cause improper and dangerous operation! Never use magnetic tip screwdriver near the Sentry 2100. The electrical connections to this boiler must
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Page 20 GT INSTALLATION AND OPERATION INSTRUCTIONS Figure 29 - Basic Heating System and Indirect Tank Wiring Multiple 4 Wire Zone Valves Multiple Zones w/ Taco Valve Controller Figure 30 shows the basic multiple zoned system uses Models ZVC403 to ZVC 406 normally closed four (4) wire zone valves. This wiring Figure 31 shows the basic multiple zoned system using system is used with the piping shown in Figure 26. normally closed 2, 3 or 4 wire Taco zone valves. This wiring system is used with t
