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GB200-IM-5
42-9184
GB200 SERIES
INSTALLATION, OPERATION
& MAINTENANCE MANUAL
WITH REPLACEMENT
PARTS LIST
GAS-FIRED STEAM
CAST IRON BOILERS
85,000 TO 165,000 BTUH INPUT
INTERMITTENT PILOT/VENT DAMPER
& STANDING PILOT/VENT DAMPER
AA
AA
TABLE OF CONTENTS
SECTION 1: INTRODUCTION Step 6: Wiring Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Code Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 SECTION 3: START-UP & OPERATION
Venting Requirements . . .
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SECTION 1: INTRODUCTION The following terms are used throughout this manual to bring When two or more appliances vent into a common flue, the attention to the presence of potential hazards or to important area of the common flue should be at least equal to the area information concerning the product: of the largest flue plus 50% of the areas of the additional flue or vent connectors. DANGER: Indicates an imminently hazardous situa- When existing boiler is removed from common venting sys- tion
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CHIMNEY REQUIREMENTS NOTE: Boiler employs atmospheric combustion. Com- bustion air must not be contaminated with halogenated DANGER: A chimney which does not meet modern hydrocarbon vapors, aerosol propellants or freon. Other- safety standards will result in a fire or deadly carbon wise, boiler heat exchanger will be subject to corrosion, monoxide poisoning of the building residents. reducing boiler life. Chimney condition is of paramount importance for a safe and WATER TREATMENT efficient boile
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SECTION 2: BOILER INSTALLATION STEP 1: LOCATING/SETTING BOILER Remove all packing material from boiler. Check that burners, Boiler may be installed in an alcove (see dimensions in Fig- draft diverter and controls are in proper position. ure 2.1). Locate boiler so connecting flue pipe between draft hood and chimney is as short as possible. Boiler shall be installed such that the gas ignition system components are protected from water (dripping, spraying, Observe the following minimum clearances
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COLD WATER FILL RETURN FIGURE 2.2: RECOMMENDED FIREPROOF BASE The supply and return lines should be equipped with drain cocks to drain sediment and sludge from lowest points of boiler. STEP 3: INSTALLING HYDRONIC COMPONENTS 6" OVERHANG OF BLOCKS A low-water cutoff must be installed to protect the unit from AND SHEETMETAL ALL dry fire. AROUND 4" HOLLOW CLAY 6" Screw extension nipple into 3/4" tapping on top of the TILE (TWO COURSES) absorption unit and install relief valve into top of nipple wit
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STEP 4: VENTING BOILER FIGURE 2.4: VENT DAMPER INSTALLATION A factory-mounted spill switch is provided on all GB200 boil- FOR INTERMITTENT PILOT ers (see Figures 2.4 & 2.4A). VENT DAMPER DANGER: Draft diverter, vent outlet and vent damper PRESSURE as supplied must not be altered in any way, as proper CONTROL SPILL boiler operation would be jeopardized. Flame rollout, SWITCH fire or carbon monoxide poisoning will result. THERMOSTAT CONNECTION The flue or vent connectors must be installed flush
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ADDITIONAL CHIMNEY REQUIREMENTS FIGURE 2.5: ATTACHING VENT DAMPER TO DRAFT Chimney condition is of paramount importance for a safe and DIVERTER & FLUE PIPE efficient boiler installation. All installations must include a chimney inspection by a qualified individual or agency. Chim- ney construction materials must be compatible with the fuel MAKE SURE MOTOR IS being used (See Figure 2.5A). LOCATED ON FRONT SIDE CLOSED OPEN FLOW DIRECTION Particular attention should be paid on all oil-to-gas conver
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FIGURE 2.7: GAS PIPE SIZING TABLES & EXAMPLE Maximum Capacity of Pipe in Cubic Feet of Natural Gas per Hour for Gas Pressures of 0.5 Psig or Less and a Pressure Drop of 0.3 Inch Water Column (Based on a 0.60 Specific Gravity Gas) Nominal Length of Pipe, Feet Internal Iron Pipe Diameter, Size, 90 100 125 175 150 200 10 20 30 40 50 60 70 80 Inches Inches 1/4" 22 18 32 15 14 12 11 11 10 9 8 8 7 6 .326 3/8" 49 40 72 34 30 27 25 23 22 21 18 17 15 14 .493 1/2" 132 63 56 50 46 43 40 38 31 28 26 .622 9
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STEP 6: WIRING BOILER For vent damper-equipped models, connect thermostat to blue leads (see Figures 2.4 & 2.4A). WARNING: Turn off electrical power supply before servicing. Contact with live electric components can NOTE: If any of original wire supplied with boiler must cause electric shock or death. be replaced, use similar wire of 105° C rating. Other- wise, insulation may melt or degrade, exposing bare All electrical and control wiring must be installed in accor- wire. dance with the codes
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FIGURE 2.10: Wiring Diagram & Operation Sequence for FIGURE 2.11: Wiring Diagram & Operation Sequence for Boilers Equipped with Intermittent Pilot, Vent Damper Boilers Equipped with Standing Pilot, Vent Damper and and 400 Series or M & M PS804 LWCO 400 Series or M & M PS804 LWCO 10
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SECTION 3: START-UP & OPERATION SEQUENCE OF OPERATION FIGURE 3.1: STEAM CONTROL ARRANGEMENT For sequence of operation of the particular boiler being installed, refer to Figures 2.8, 2.9, 2.10 and 2.11 in Section 2 PRESSURE PRESSURE RELIEF VALVE of this manual. CONTROL Spill and rollout switches are mounted on all GB200 boilers. PRESSURE GAUGE The spill switch detects the escape of combustion products through the draft diverter relief opening and interrupts the power to the gas valve preventing
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FIGURE 3.2: BURNER FLAME COMPARISON/PILOT FLAME Q3451B Q314A/Q309A CONSTANT PILOT INTERMITTENT MODELS IGNITION PILOT MODELS NORMAL PILOT FLAME NORMAL LIFTING YELLOW YELLOW TIPPING FLAME (HARD FLAME) (TOO MUCH AIR) (MARGINAL) (TOO LITTLE AIR) MAIN BURNER FLAMES Example: A GB200-4L boiler takes 5 minutes, 27 seconds to 9. Start and stop burners several times by raising and low- use 10 cubic feet of natural gas. The local utility indicated the ering the thermostat setting. heating value of the na
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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 knob, never use tools. If the knob will not push in or turn some gas is heavier than air and will settle on the floor. by hand don’t try to repair it, call a qualified service tech- What to
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OPERATING INSTRUCTIONS Intermittent Pilot - Honeywell VR8204 Natural or Propane Gas 1. STOP! Read the safety information on page 13.. INTERMITTENT PILOT - HONEYWELL VR8204 2. Set the thermostat to lowest setting. 3. Turn off all electric power to the appliance. 4. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. 5. Remove control access panel (if applicable). INLET 6. Rotate gas control knob clockwise to “OFF”. GAS O
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4. Check gas manifold for proper position and reassemble 11. Remove vent drain piping and reinstall pressure relief burners to the manifold. Line up holes in burners with the ori- valve. Open gate valves on supply and return lines. Turn on fices, and slide assembly back into position. Be sure to rein- burner. System is now ready to operate. stall burners with burner ports on the top surface (upright). HOW TO CHANGE ORIFICES 1. Shut off power supply and gas supply to the boiler. 5. When a low w
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ORDERING INFORMATION: When ordering parts, provide GB200 Series model and serial number shown on unit rating plate as well as part number and name as shown in parts list. Parts may REPLACEMENT PARTS LIST be obtained from your local Smith heating contractor. MODEL GB200 SERIES REPLACEMENT PARTS LIST REF NO. NAME OF PART PART NO. GB200-3 GB200-4L GB200-4H GB200-5 1 Jacket - Complete 59248 1 Jacket - Comp
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REF NO. NAME OF PART PART NO. GB200-3 GB200-4L GB200-4H GB200-5 Standing Pilot 5 Pilot Ass'y NG- Q314ALB, Q309A 72364 1 1 1 Pilot Ass'y NG- Q314ALB, Q309A 72365 1 Pilot Ass'y LP- Q314ALB, Q309A 72370 1111 Pilot Ass'y LP- Q314ALB, Q309D 72371 1 — Thermocouple K16RA-30D 59109 1 1 1 Thermocouple K16RA-36D 51006 1 9 Gas Valve - NG VR8200H-1129 NG/LP* 59129 1111 28 Transformer 115/24 V, 43VA 50172 1111 Hone
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FIGURE 1: GB200 GENERAL ASSEMBLY 32 26 27 33 20 23 1 24 22 15 31 30 25 21 28 16 11 17 12 13 14 30 34 4 3 5 6 2 10 8 9 18
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19
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WARNING 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 toxic. If your Smith boiler is not working properly, or is not vented properly, dangerous levels of CO may accumulate. CO is lighter than air and thus may travel throughout the building. Brief exposure to high concentrations of CO, or prolonged exposure to lesser amounts of CO, may resu
