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GB300-IOM-4
GB300
NATURAL OR PROPANE GAS BOILER
INSTALLATION & OPERATING MANUAL
Designed and tested according to A.S.M.E. Boiler and Pressure Vessel Code, Section
IV for a maximum allowable working pressure of 80 psi US, 50 psi Canada water,
15 psi steam.
CAUTION: Do not use automotive anti-freeze in the boiler waterways. If the use of
antifreeze is necessary an anti-freeze specifically formulated for hydronic heating
systems must be used!
Water treatment is not recommended. This boiler uses gas
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Page 2 GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Assurez-vous de bien suivre les instructions données dans cette notice pour réduire au minimum le risque d'incendie ou d'explosion ou pour éviter tout dommoge matériel, toute blessure ou la mort Ne pas entreposer ni utiliser d'essence ou ni d'autres vapeurs ou liquides inflammables à proximité de cet appareil ou de tout autre appareil. QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ: • Ne pas tenter d'allumer d'appareil. • Ne touchez à aucun
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Page 3 GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS WARNING: Never install a GB300(S,W) boiler on BOILER RATINGS & CAPACITIES top of combustible flooring! Failure to comply Before undertaking the installation of the GB300(S,W) with this warning may result in a fire causing boiler check the boiler rating plate to ensure that the boiler extensive property damage, severe personal has been sized properly for the job. The rating label has injury or death! been packed with the controls. The “N
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Page 4 GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Each opening must have a minimum free area of COMBUSTION AIR & VENTILATION 2 1 in /1000 Btu/hr, 2200 mm2/kW based on the total input rating of ALL gas utilization equipment in the WARNING: This boiler must be supplied with confined area. Each opening must be no less than combustion air in accordance with Section 5.3, 2 2 100 in , 64,516 mm in size. The upper opening must be Air for Combustion & Ventilation, of the latest within 12 in, 3
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Page 5 GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS When more than one appliance is connected to the same CHIMNEY & VENT PIPE CONNECTIONS chimney flue the flue must be large enough to safely vent the combined output of all the appliances. WARNING: The vent installation must be in accordance with Part 7, Venting of Equipment, of WARNING: If an appliance using any type of a the National Fuel Gas Code, ANSI Z223.1/NFPA54- mechanical draft system operating under latest revision or applicable
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Page 6 GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS c. Where it is practical, close all building doors and COMMON VENT SYSTEMS windows and all doors between the space in which If an existing boiler is removed from a common venting the appliances remaining connected to the common system, the common venting system may then be too venting system are located and other spaces of the large for the proper venting of the remaining appliances building. Turn on clothes dryers and any appliance con
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Page 7 GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS e. Test for spillage at the draft hood relief opening after g. Any improper operation of the common venting 5 minutes of main burner operation. Use the flame system should be corrected so the installation of a match or candle, or smoke from a cigarette, cigar conforms with the National Fuel Gas Code, ANSI or pipe. Z223.1/NFPA 54. When resizing any portion of the common venting system, the common venting Faire fonctionner le brûleur prin
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Page 8 GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 2B Dual Flue Outlets And Inside Air (GB300 Series) 2 FT 0.6 m 10 FT 3.4 m 3 FT 0.9 m 5 FT 4.5 m Figure 2C Vertical Venting Using A Masonry Chimney And Inside Air (GB300 Series) 10 FT 3.1 m 3 FT 0.9 m 3 FT 0.9 m
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Page 9 GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS 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 Figure 2E Common Vents And Inside Air (GB300 Series) 10 FT 3.1 m 3 FT 0.9 m 3 FT 0.9 m
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Page 10 GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 2F Dual Flue Outlets With Two Boilers Using A Masonry Chimney And Inside Air (GB300 Series) 10 FT 3.1 m 3 FT 0.9 m 3 FT 0.9 m Figure 2G Horizontal Venting And Inside Air (GB300) BUILDING OVERHANG 4 FT 1.2 M MAX. PITCH PIPE DOWN TOWARDS TERMINAL CAP 1/4 IN. PER FOOT 20MM/M OF RUN TO ALLOW FOR CONDENSATE DRAINAGE 3 FT 0.9 m 3 FT 0.9 m 1.5 FT 0.5m MINIMUM DISTANCE FROM EXHAUST TO MAXIMUM SNOW LINE.
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Page 11 GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS A box with a number from 63265 to 63272, Burner Base BOILER ASSEMBLY Panels Less Sides, contains the burner base front and Locate the boiler installation site based on the guidelines rear panels and the burner base baffle, Figure 4. set forth in the previous pages. A full concrete block foundation is recommended to protect the boiler from Figure 4 Burner Base Box 63265 to 63272 moisture and debris. Use solid blocks to support the boile
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Page 12 GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Burner Base Assembly 5 through 12 Sections Figure 8 Burner Base Rear Panel Detail, 5 - 12 Sect 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 level to ensure that the burner base panels are plumb before tightening the stainless steel nuts and bolts. The factory installed refractory retention bracket
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Page 13 GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Burner Base Assembly 13 through 21 Sections With the burner base intermediate channel and baffles Box 72694, X7 Splice Channels, contains the burner level, attach the front and rear channels to the base front, intermediate and rear channels and intermediate channel. Bolt the burner base side panels additional 5/16" nuts and bolts, Figure 10. to the base baffles, Figure 12. Figure 10 X7 Box 72694 Figure 12 Burner Base Baffle Front and R
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Page 14 GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Bolt the front and rear base panels in place, Figure 13. Figure 13B Center the factory installed refractory retention brackets on the rear base panel so that the bracket is in the middle of each refractory board Figure 13B. Figure 13A Burner Base, Side Front and Rear 13 to 21 Sections Panel Assembly Figure 14A Base Rear Channel Bolt Holes Figure 14B Base Rear Channel NOTE: Do not install the two lower bolts in the base rear panel, Fi
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Page 15 GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS NOTE: The base front panels bolt to the inside of the Figure 18 Manifold Attachments front base splice channel, Figure 15. Figures 15 Base Front Panel Detail Locate the Burner Box. It is marked with a number from 72724 to 72731. Install three burner 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 Use a spirit level to plumb the front and rear panels base r
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Page 16 GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Bolt the insulation splice panel bracket to the front base Figure 22B Burner Base Splice Insulation Boards channel, Figure 21. Install the two insulation boards in the spaces between the two front and two rear burner base panels. Firmly but carefully press the insulation boards in place and insert the nails through the top and bottom holes, Figure 22A&B. Orientate and install splice refractory retainer. Center the retainer over the spl
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Page 17 GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Ceramic Blanket Installation Figure 25 Ceramic Blanket Placement Before installing the cast iron sections a ceramic blanket gasket must be installed on the burner base. Locate the roll of ceramic blanket and can of spray adhesive supplied in the X1 box. Spray two heavy coats of adhesive on the top of the burner base waiting for the adhesive to tack up between coats, Figure 23. Figure 23 Ceramic Blanket Adhesive Application Cast Iron Se
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Page 18 GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 26B Marking Burner Base Rear Midpoint Figure 28 Ceramic Rope Application Apply two coats of the spray adhesive supplied with the Figure 29 Trimming Ceramic Rope boiler to the rope seal grooves, Figure 27. Allow time for the first coat to become tacky before applying the second coat. CAUTION: Do not get any of the spray adhesive in the seal ports or premature failure of the seals may occur voiding the warranty! Figure 27 Ceramic
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Page 19 GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS To ensure that the assembled sections will be centered Figure 33 Front View - Odd Numbered Models on the burner base the cast iron sections should be assembled from the midpoint of the burner base outward. On boilers having an even number of sections the first intermediate section should be placed so it’s side surface lines up with the midpoint marked on the burner base front and rear panels, Figures 31 and 32. For boilers having an od
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Page 20 GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 36 Lower Port Seal Placement Install the draw rods, nuts and washer and slightly tighten the nuts. Only one washer is to be placed on each draw rod, Figure 38, to torque sections together. Figure 38 Draw Rod Installation Figure 37 Upper Port Seal Placement Table 3 Steam Riser, Flue Collector Bracket & Jacket Splice Channel Bracket Locations Section Numbered from Left to Right Boiler Model 123456789 10 11 12 13 14 15 16 17 18 19
