28A-IOM-7
MEA#273-89-E
SERIES 28A
GAS OR OIL BOILER
INSTALLATION & OPERATING
INSTRUCTIONS
DESIGNED AND TESTED ACCORDING TO A.S.M.E. BOILER AND PRESSURE
VESSEL CODE, SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE
OF: 15 PSI STEAM OR 80 PSI WATER.
TO INSTALLER
READ THESE INSTRUCTIONS CAREFULLY. THEY WILL
SAVEYOU VALUABLE TIME WHEN ASSEMBLING THE BOILER.
WARNING: If the information in this manual is not followed exactly, a fire or explosion
may result causing property damage, personal injury or loss of life.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
this or any other appliance.
WHAT TO DO IFYOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch. Do not use any phone in your building.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas
supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER.
CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.
FOR JACKET ASSEMBLY AND BURNER SET UP SEE SEPARATE INSTRUCTIONS.
WESTCAST, INC.
260 NORTH ELM STREET WESTFIELD, MA 01085
TEL. (413) 562-9631 FAX (413) 562-3799
In Canada: 5211 Creekbank Road, Mississauga, Ont. L4W 1R3 (905) 625-2991 Fax (905) 625-6610
Page 3
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Figure 1- Service Clearances to Adjacent Construction
COMBUSTION AIR & VENTILATION
WARNING: Never install a 28A boiler on top of
combustible flooring without consulting the
local building authorities for proper installation
guidelines! A minimum clearance of 6 in,
0.15 m must be maintained between the boiler
and combustible construction. Failure to comply
with this warning may result in a fire causing
extensive property damage, severe personal
injury or death!
WARNING: This boiler must be supplied with
combustion and ventilation air in accordance
with Section 5.3, Air for Combustion &
Ventilation, of the latest revision of the National
Fuel Gas Code, ANSI Z223.1/NFPA 54 and all
applicable local building codes. Canadian
installations must comply with CAN/CGA B149.1
or .2 Installation Code. Failure to provide
adequate combustion air for this boiler can
result in excessive levels of carbon monoxide
which can result in severe personal injury or
death!
4. DO NOT install this boiler in a location that would
subject any of the electrical components to direct
contact with water or excessive moisture during
operation or servicing.
To operate properly and safely this boiler requires a
continuous supply of air for combustion. An adequate
supply of air must be available to replace the air used
by the combustion process. NEVER store objects on or
around the boiler.
5. DO NOT place this boiler in a location that would
restrict the introduction of combustion air into the
boiler.
WARNING: Never store combustible materials,
gasoline or any product containing flammable
vapors or liquids in the vicinity of the boiler.
Failure to comply with this warning can result
in an explosion or fire causing extensive
property damage, severe personal injury or
death!
CAUTION: Never use an exhaust fan in the boiler
room. The boiler room must never be under a
negative pressure or improper burner operation will
occur!
NOTE: Forced make-up air supplied to the boiler
room must be approved by the local authorities. A
minimum of 30 ft3/GAL, 0.22 m3/L for oil or
20 ft3/100 MBH (Therm), 0.024 m3/kW for gas must
be provided.
Page 4
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
All Air From Inside The Building
If the boiler is to be located in a confined space mini-
Table 1- Make-up Air Louver Sizing
Required Cross Sectional Area (in2)
mum clearances of 24 in, 610 mm must be maintained
between the boiler and any adjacent construction. When
installed in a confined space, two permanent openings
communicating with an additional room(s) are required.
The combined volume of these spaces must have
sufficient volume to meet the criteria for an unconfined
space. The total air requirements of all fuel burning
equipment or any type of exhaust fan must be
considered when making this determination.
Metal
Louvers
75% Free Area
333
Wooden
Input
(MBH)
1000
1200
1400
1600
1800
2000
2200
2400
2600
2800
3000
3200
3400
3600
3800
4000
4200
4400
4600
4800
1/4" Wire
Screen
250
Louvers
25% Free Area
1000
1200
1400
1600
1800
2000
2200
2400
2600
2800
3000
3200
3400
3600
3800
4000
4200
4400
4600
4800
300
350
400
450
500
550
600
650
700
750
800
850
900
950
400
467
533
600
667
733
800
867
Each opening must have a minimum free area of 1 in2/
1000 Btu/hr, 140 in2/GPH, 2200 mm2/kW based on the
total input rating of ALL fuel burning equipment in the
confined area. Each opening must be no less than 100
in2, 64,516 mm2 in size. The upper opening must be
within 12 in, 305 mm of, but not less than 3 in, 76 mm
from, the top of the enclosure.
934
1000
1066
1134
1200
1267
1334
1400
1467
1533
1600
The bottom opening must be within 12 in, 305 mm of,
but not less than 3 in, 76 mm from, the bottom of the
enclosure.
1000
1050
1100
1150
1200
All Air From Outside The Building
When installed in a confined space Two permanent
openings communicating directly with, or by ducts to,
the outdoors or spaces that freely communicate with the
outdoors must be present. The upper opening must be
within 12 in, 305 mm of, but not less than 3 in, 76 mm
from, the top of the enclosure. The bottom opening must
be within 12 in, 305 mm of, but not less than 3 in,
76 mm from, the bottom of the enclosure.
CHIMNEY & VENT PIPE
CONNECTIONS
WARNING: The vent installation must be in
accordance with Part 7, Venting of Equipment,
of the National Fuel Gas Code, ANSI Z223.1/
NFPA 54-latest revision, the ASHRAE Equipment
Handbook on Venting or applicable provisions
of the local building codes. Canadian
installations must comply with CAN/CGA B149.1
or .2 Installation Code. Improper venting of this
boiler can result in excessive levels of carbon
monoxide which can result in severe personal
injury or death!
Where directly communicating with the outdoors or
communicating with the outdoors through vertical ducts,
each opening shall have a minimum free area of 1 in2/
4000 Btu/hr, 35 in2/GPH, 550 mm2/kW of the total input
rating of all of the equipment in the enclosure.
Where communicating with the outdoors through
horizontal ducts, each opening shall have a minimum
free area of 1 in2/2000 Btu/hr, 70 in2/GPH, 1100 mm2/
kW of the total input rating of all of the equipment in
the enclosure. When ducts are used, they must have the
same cross-sectional area as the free area of the
opening to which they connect. When calculating the
free area necessary to meet the make-up air
requirements of the enclosure, consideration must be
given to the blockage effects of louvers, grills and
screens. Screens must have a minimum mesh size of
1/4 in, 6.4mm. If the free area through a louver or grill
is not known the louver or grill should be sized per Table 1.
CAUTION: The products of combustion from a 28A
must be safely vented to the outdoors while
ensuring that the flue gasses do not cool
prematurely. It’s critical that the chimney system be
properly designed to handle the flue gases. An
oversized or uninsulated chimney can cause the
moisture in the flue gases to condense resulting in
damage to the chimney system unless it’s
specifically designed for condensate. If this is the
case a suitable condensate drain must be used to
protect the boiler from condensate.
NOTE: Our warranty does not cover corrosion
damage to the boiler or its vent system caused by
flue gas condensate!
Page 5
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Chimney Inspection & Sizing
The 28A is designed for pressurized operation with a
If this boiler will be connected to a masonry chimney, a
thorough inspection of the chimney must be performed.
Ensure that the chimney is clean, properly constructed,
lined and properly sized, see Figure 2. Table 2 lists the
equivalent breeching and flue sizes required for the 28A
boilers.
back pressure of 0.10 in, 2.54 mm W.C. before the
smoke hood slide damper. If the vent configuration
results in a back pressure greater than this, the burner
capacity may have to be verified. Contact the Smith
Technical Service Department to verify the burner
capacity.
Table 2 - Equivalent Breeching & Chimney Size
The chimney must be able to provide 0.10" WC at the
boiler outlet. If the chimney is 50 ft. or taller it may
produce excessive draft (approx. - 0.25" WC) and a
barometric draft regulator may be needed.
Boiler Model
Breeching Size
Chimney Size
in
mm
254
254
254
305
305
356
356
356
356
356
406
406
406
406
457
in
mm
254
254
254
305
305
356
356
356
356
356
406
406
406
406
457
28A-4
28A-5
28A-6
28A-7
28A-8
28A-9
28A-10
28A-11
28A-12
28A-13
28A-14
28A-15
28A-16
28A-17
28A-18
10
10
10
12
12
14
14
14
14
14
16
16
16
18
18
10
10
10
12
12
14
14
14
14
14
16
16
16
18
18
When more than one appliance is connected to the
same chimney flue the flue must be large enough to
safely vent the combined output of all the appliances.
WARNING: If an appliance using any type of
a mechanical draft system operating under
positive pressure is connected to a chimney
flue, never connect a Category I appliance to
this flue. Doing so can result in the
accumulation of carbon monoxide which can
cause severe personal injury or death!
Note: These sizes are based on a 20 foot chimney height.
Figure 2 - Vertical Venting
Page 6
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
WARNING: Failure to maintain minimum
VENT CONNECTIONS
clearances between vent connectors and any
combustible material can result in a fire causing
extensive property damage, severe personal
injury or death!
WARNING: Never modify or alter any part of the
boiler’s smoke hood. This includes the removal
or alteration of any baffles. Never install a vent
pipe of a diameter different than that of the
boiler smoke hood outlet. Failure to comply with
this warning can result in severe personal injury
or death.
COMMON VENT SYSTEMS
If an existing boiler is removed from a common venting
system, the common venting system may then be too
large for the proper venting of the remaining appliances
connected to it. At the time of removal of an existing
boiler, the following steps shall be followed with each
appliance remaining connected to the common venting
system placed in operation, while the other appliances
remaining connected to the common venting system are
not in operation.
Locate the boiler as close to the chimney as possible.
Use the shortest, straightest vent connector possible for
the installation. If horizontal runs exceed 5 ft, 1.5 m they
must be supported at 3 ft, 0.9 m intervals with overhead
hangers. Use a single wall stainless or single wall
galvanized steel vent pipe the same diameter as the flue
collar to connect the boiler to a masonry chimney. When
using an approved metal chimney system use the
appropriate vent connector. The vent connector should
be sloped up toward the chimney at a minimum rate of
1/4 in/ft, 2 cm/m. On masonry chimneys the connector
must terminate flush with the inside of the chimney flue.
Fasten each single wall vent connection with at least 3
corrosion resistant sheet metal screws.
Au moment du retrait d'une chaudière existante, les
mesures suivantes doivent être prises pour chaque
appareil toujours raccordé au système d'évacuation
commun et qui fonctionne alors que d'autres appareils
toujours raccordés au système d'évacuation ne
fonctionnent pas: système d'évacuation
a) Seal any unused openings in the common venting
system.
The vent materials used in positive pressure vent
systems must be certified to UL 1738 for installations
in the United States, ULS636 for installations in Canada.
The following manufactures have systems that meet
these requirements:
Sceller toutes les ouvertures non utilisées du
système d'évacuation.
b) Visually inspect the venting system for proper size
and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion and other
deficiencies which could cause an unsafe condition.
Heat-Fab, Inc.
38 Hayward Street
Greenfield, MA 01301, (800) 772-0739.
Z-Flex U.S., Inc.
20 Commerce Park
North, Bedford, NH 03110-6911, (800) 654-5600.
Inspecter de façon visuelle le système d'évacuation
pour déterminer la grosser et l'inclinaison
horizontale qui conviennent et s'assurer que le
système est exempt d'obstruction, d'étranglement
de fruite, de corrosion et autres défaillances qui
pourraient présenter des risques.
Protech Systems Inc.
26 Gansevoort Street,
Albany, NY 12202 (518) 463-7284
WARNING: Breeching under positive pressure
must be certified to UL 1738 for installations in
the United States, ULS636 for installations in
Canada. Type B1 vent SHALL NOT be used.
Failure to comply with this warning can result
in severe personal injury or death.
Always provide a minimum clearance of 6 inches
between single wall metal vent pipe and all combustible
materials.
Page 7
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
c) Insofar as is practical, close all building doors and
g) Any improper operation of the venting system
windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn
on any exhaust fans, such as range hoods and
bathroom exhaust, so they will operate at maximum
speed. Do not operate a summer exhaust fan for a
boiler installation. Close fireplace dampers.
should be corrected so the installation conforms with
the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
When resizing any portion of the common venting
system, the common venting system should be
resized to approach the minimum size as
determined using the appropriate tables in
Appendix F in the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and or CSA B149 Installation
Codes.
Dans la mesure du possible, fermer toutes les
portes et les fenêtres du bâtiment et toutes les
portes entre l'espace où les appareils toujours
raccordés du système d'évacuation sont installés et
les autres espaces du bâtiment. Mettre en marche
les sécheuses, tous les appareils non raccordés au
système d'évacuation commun et tous les
ventilateurs d'extraction comme les hottes de
cuisinère et les ventilateurs des salles de bain.
S'assurer que ces ventilateurs fonctionnent à la
vitesse maximale. Ne pas faire fonctionner les
ventilateurs d'été. Fermer les registres des
cheminées.
Tout mauvais fonctionnement du systéme
d'évacution commun devrait étré corrigé de façor
que l'installation soit conforme au National Fue Gas
Code, ANSI Z223.1/NFPA 54 et (ou) aux codes
d'installation CAN/CGA-B149. Si la grosseur d'une
section du système d' évacuation doit étré modifiée,
le système devrait étré modifié pour respecter les
valeurs minimales des tableaux pertinents de
l'appendice F du National Fuel Gas Code, ANSI
Z223.1/NFPA 54 et (ou) des codes d'installation
CSA-B149.
BOILER ASSEMBLY
Locate the boiler installation site based on the guide-
lines set forth in the BOILER LOCATION section.
d) Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat so
appliance will operate continuously.
WARNING: Never install a 28A boiler on top of
combustible flooring without consulting the
local building authorities for proper installation
guidelines! Failure to comply with this warning
can result in a fire causing extensive property
damage, severe personal injury or death!
Mettre l'appareil inspecté en marche. Suivre les
instructions d'allumage. Régler le thermostat de
façon que l'appareil fonctionne de façon continue.
e) Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the flame
of a match or candle, or smoke from a cigarette,
cigar or pipe.
Packaged Boilers/Factory Assembled Sections
A careful inspection of all assemblies should be made
to detect possible shipping damage. Packaged boilers
and factory assembled blocks of sections are
hydrostatically tested at the factory to insure pressure
tightness. A hydrostatic retest should be performed
before any piping connections are made to detect leaks
caused by shipping.
Faire fonctionner le brûleur principal pendant 5 min
ensuite, déterminer si le coupetirage déborde à
l'ouverture de décharge. Utiliser la flamme d'une
allunette ou d'une chandelle ou la fumée d'une
cigarette, d'un cigare ou d'une pipe.
NOTE: All assembled boiler sections shall pass the
hydrostatic tests prescribed in Section IV of the
ASME Boiler and Pressure Vessel Code.
f) After it has been determined that each appliance
remaining connected to the common venting
system properly vents when tested as outlined
above, return doors, windows, exhaust fans,
fireplace dampers and any other gas-burning
appliance to their previous condition of use.
CAUTION: Do not connect any boiler controls during
the pressure test or they will be damaged!
Une fois qu'il a été d éterminé, selon la métode
indiquée cidessus, que chaque appareil raccordé
au système d'évacuation est mis à l'air libre de façor
adéquate. Remettre les portes et les fenêtres, les
ventilateurs, les registres de cheminées et les
appareils au gaz à leur position originale.
Page 8
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Completed boilers must be tested as follows:
Steam Boilers – the assembled boiler sections shall be
2. Carefully place the back section in position on the
angles as shown in Figure 4.
subjected to a hydrostatic test pressure of not less than
45 psig, 315 kPa.
WARNING:The section MUST be fully supported
to prevent it from falling! Failure to comply with
this warning may result property damage,
severe personal injury or death!
Water Boilers – the assembled boiler sections shall be
subjected to a hydrostatic test pressure of not less than
1 1/2 times the maximum allowable working pressure.
Figure 4 - Section Placement
The hydrostatic pressure shall not exceed the required
test pressure by more than 10 psig, 70 kPa during the
test.
WARNING: Never leak test the boiler using
compressed air! Failure to comply with this
warning may result in property damage, severe
personal injury or death!
1. Plug all openings in the boiler and fill it with water.
2. Bleed any air off through one of the top tappings
then increase the pressure as outlined above.
3. Clean the hydronic port connector sealing surfaces
and the rope grooves with a wire brush to remove
any rust or debris.
3. Maintain the test pressure while carefully checking
for leaks. If a leak is found it must be eliminated,
see Table 4 and supporting text. Once the
assembled boiler sections pass the hydrostatic test
drain them and remove the plugs from any tappings
that will be used in service.
4. Apply two coats of the spray adhesive supplied with
the boiler to the rope groove. Allow time for the first
coat to dry before applying the second coat. When
the second coat is tacky press the rope into the rope
groove. Trim the rope off leaving 1/8 in., 3.2 mm
extending beyond the surface of the cast iron
section, Figure 5.
NOTE: The shipping lugs, lifting lugs and metal
banding should be removed before installing the
jacket on factory assembled sections.
Figure 5 - Rope Installation
CAUTION: Remove the left jacket panels on fully
packaged boilers and ensure that the cleanout
covers are secure and gas tight. Loose covers could
damage the boiler.
Assembly of Knocked-Down Boilers
Drilled and tapped steel angles are furnished to provide
a level footing, ease of section assembly and a point of
jacket attachment.
1. Set the angles as shown in Figure 3. They must be
parallel and level. Grout under the angles to provide
a continuous bearing surface.
Figure 3 - Steel Angle Placement
Page 9
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
5. Insert the large port connector with its steel inner
Figure 6 - Section Alignment
ring into the upper port.
6. Insert the two round port connectors into the lower
ports.
NOTE: Apply the spray adhesive supplied with the
boiler to the port recess to hold the port connector
in place if necessary.
7. Select the correct intermediate section and carefully
Table 4 - Section Torque Sequence
move it into place against the back section, Figure
4.
Step
Rod Position
Torque
ft lbs
25
25
25
10
50
50
50
75
75
75
30
125
125
125
125
40
Nm
34
34
34
14
68
68
68
102
102
102
42
169
169
169
169
54
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Upper Right
Lower Left
Lower Right
Upper Left
Upper Right
Lower Left
Lower Right
Upper Right
Lower Left
Lower Right
Upper Left
Upper Right
Lower Left
Lower Right
Upper Right
Upper Left
CAUTION: Any steam uptake and heater sections
must be located as shown in Table 3. Failure to
comply with this caution may result in poor boiler
performance and prevent the jacket from fitting!
Only one intermediate section with an external leg
boss has been included. It should be located toward
the front of the boiler for optional low water cutoff
use. See Table 3.
NOTE: A putty knife or similar tool can be used to
hold the port connectors in place while the
intermediate section is positioned. It must be
removed before the sections make contact or the
port connector will be damaged resulting in a leak!
8. Insert the four draw rods through the casting
bosses. Thread nuts onto one end of the rods. Place
washers on the other end of the rods before
threading nuts onto them. Snug the nuts finger tight.
Use a spirit level to ensure that the first two sections
are plumb and properly aligned, Figure 6. Check the
rope to insure that it’s properly positioned. Once the
sections are plumb and the rope and port
connectors are properly positioned follow the torque
sequence shown in Table 4.
NOTE: With these initial torques the sections may
not be metal to metal, which is acceptable. If any of
the ports leak during the hydrostatic test the torque
can be increased to 200 ft lbs, 271 Nm on the upper
right rod.The torque on the lower left and right rods
can be increased to 150 ft lbs, 203 Nm. Once the
sections are metal to metal additional torque will not
improve the seal.
Table 3 - Section Locations
Boiler
Model
28A-4
Section Location Numbered From Front To Back
1
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
2
T
3
H
T
H
H
H
H
T
T
T
T
T
T
T
T
T
4
B
H
T
5
6
7
8
9
10
11
F
12
13
14
15
16
17
18
Front Section
28A-5
H
T
B
H
T
T
Intermediate Section w/ 5" Tapping & Boss
Intermediate Section w/ Heater Opening
Intermediate Section, Plain
28A-6
B
H
T
H
P
B
28A-7
T
P
P
P
H
H
H
H
H
H
H
H
H
B
H
T
P
P
H
T
T
P
P
P
P
28A-8
T
H
H
P
P
P
P
P
P
P
P
P
B
H
T
Back Section
28A-9
T
P
H
T
B
H
T
H
P
P
H
T
T
P
28A-10
28A-11
28A-12
28A-13
28A-14
28A-15
28A-16
28A-17
28A-18
H
H
H
H
H
H
H
H
H
B
H
T
B
H
T
T
P
P
H
T
B
H
H
H
H
H
H
H
H
P
H
H
T
H
T
B
H
T
P
H
P
P
H
B
H
T
P
H
H
P
B
H
T
H
H
H
P
P
H
B
H
T
H
P
B
H
H
B
Page 10
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
9. Assemble the rest of the sections following steps 3
through 8 above.
Burner Mounting Plate Installation, Figure 8
1. Apply two coats of the spray adhesive supplied with
the boiler to the rope groove on the plate. Allow time
for the first coat to dry then apply the second coat.
When the second coat is tacky lay the 3/8 rope into
the rope groove and press it into place.
10. Hydrostatically test the boiler by following the
instructions on page 8.
11. While the boiler is being filled confirm that all
of the draw rods are properly torqued and that
there are no leaks.
2. Screw the four 7/16-14 x 2 1/2" studs into the
tapped holes in the boiler front section, Figure 8.
12. If any leaks are found tighten the draw rods on that
section until the leak stops.
3. Install the burner mounting plate insulation block in
the burner opening in the front section of the boiler.
The small observation port cutout must be on the
top, left side.
Cleanout Cover Installation
1. The cleanout covers come insulated from the
factory. Inspect the covers to ensure that the
insulation is not damaged or missing. If it is call the
Smith Customer Service Department.
4. Align the four holes in the burner mounting plate
with the 7/16" studs and force the burner insulation
block inward until the studs extend far enough
through the burner mounting plate holes so the nuts
can be started. Lightly tighten the nuts.
2. Trim the 1/2" rope that's sticking out around the
cleanout opening flush with the castings to insure
an air-tight seal, see Figure 5.
5. Carefully insert the 1/4-20 x 5" machine screws
through the holes in the burner mounting plate and
insulation block, Figure 8. Reach through the inside
of the burner opening and install the stainless steel
fender washers and nuts and snug the nuts down.
3. Install the cleanout cover bolts from the inside of the
cleanout cover and start the nuts, Figure 7.
4. Insert the cleanout cover and tighten the nuts to
15 ft lbs, 21 Nm.
CAUTION: The burner insulation block must be
supported from the inside to prevent it from tearing.
Don't force the bolts through the block or over
tighten the nuts or the block with be damaged!
5. Apply a bead of high temperature silicone caulk
around the perimeter of the cleanout cover to
ensure an air tight seal.
Figure 7 - Cleanout Cover Assembly
Page 11
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Figure 8 - Burner Mounting Plate Details
Observation Port Assembly, Figure 9
1. Position the hinged end of the steel flapper door,
# 5, over the boss on the observation port cover,
# 4.
Figure 9 - Observation Port Assembly
2. Drive the expansion pin, # 7, through the hinge
bosses to secure the door to the cover.
3. Insert the hex bolt, # 6, through the hole in the
observation port cover.
4. Install the spring, nut and knob, #"s 3, 2 & 1 on the
bolt as shown. Use the nut as a jam nut against the
knob.
5. Apply the insulating tape to the back of the
observation port cover as shown.
Page 12
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Observation Port Installation
1. Screw the four 5/16-18 x 1 1/2 studs into the tapped
Smokehood Installation, Figure 10
1. Screw the four 5/16-18 x 1 1/2 studs into the tapped
holes around the smokehood opening in the back
section.
holes around the observation cover opening in the
back section.
2. Place the observation port cover assembly over the
studs and install the washers and nuts. Tighten the
nuts uniformly.
2. Apply smokehood insulation tape to smokehood.
3. Place the smokehood over the studs and install the
washers and nuts. Tighten the nuts uniformly.
4. Apply the 1/8" x 3/4" x 18" strip of insulating tape
to the damper anchoring angle, Figure 10.
5. Fully open the slide damper and leave it ready for
adjustment during burner light off.
Figure 10 - Smokehood Assembly
Page 13
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Tankless Heater Installation - Optional
5. Install the operating control in one of the heater
1. Clean the heater flange to remove any rust or
debris.
mounting plates to ensure quick burner response
when there is a demand for hot water. Figure 12
illustrates an acceptable piping arrangement for
multiple heaters.
2. Install the four 7/16" x 1 1/2" studs into the tapped
holes in the tankless heater flange on the section,
Figure 11.
Burner Mounting
1. Clean the burner mounting flange to remove any
rust or debris.
Figure 11 - Tankless Heater Installation
2. Install the four 3/8" x 1 1/4" studs into the tapped
holes in the burner mounting plate.
3. Use a hacksaw blade, or some other suitable tool,
to properly size the opening in the burner mounting
plate insulation block to match the burner air tube
end diameter.
NOTE:The opening should be a close fit, but not too
snug or the insulation block may be damaged upon
burner insertion!
4. Place the burner gasket, supplied with the burner,
over the studs and carefully insert the burner into
the opening in the burner mounting plate.
3. Place the heater gasket over the studs and carefully
install the heater.
4. Install the nuts and tighten evenly to ensure uniform
compression of the gasket.
CAUTION: Most burners require support to the floor.
Follow the burner manufacturer’s instructions or the
burner may be damaged!
5. Install the 3/8" washers and nuts and tighten
securely.
Figure 12 - Multiple Tankless Heater Piping
Page 14
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Figure 14 - Back Section Tapping Locations
GENERAL PIPING REQUIREMENTS
CAUTION: Never use automotive antifreeze in the
boiler or heating system. If antifreeze is necessary
it must be formulated specifically for hydronic
heating systems, such as ethylene or propylene
glycol. Failure to comply with this caution will void
the warranty!
All heating system piping must be installed by a qualified
technician in accordance with the latest revision of the
ANSI/ASME Boiler and Pressure Vessel Code, Section
IV. Also ANSI/ASME CSD-1, Standard for Controls and
Safety Devices for Automatically Fired Boilers where
required. All applicable local codes and ordinances must
also be followed. A minimum clearance of 1" must be
maintained between heating system pipes and all
combustible construction.
CAUTION: Improper piping of this boiler can result
in poor performance and premature failure of the
boiler voiding the warranty! Improper piping can
also cause flooding and extensive property damage!
Ensure that the boiler is level from front to back and from
side to side. Use metal shims to level the boiler. NEVER
use wood, plastic or other combustible materials as
shims.
Table 5 - Water & Steam Tappings
Tapping Size
Water
Steam
1
2
3
4
1/8"
3/4"
3/4"
Chamber Pressure
Chamber Pressure
Probe LWCO
If a boiler is installed above any radiation elements it
must be fitted with a low water cutoff device.
Temp./Pressure Gage
3/4" Operating Control - Top
Water Glass
Manuel Reset High
Limit & Steam Gage
Water Column - Top
Skim Tapping
Manuel Reset
NOTE: Install the observation port assembly before
making any return piping connections as access
may be blocked by piping.
5
3/4"
High Limit
6
7
1"
6"
Air Removal
Water Supply
Tankless Heater
Operating Control
Figure 13 - Front Section Tapping Locations
8
3/4"
9
1 1/2"
1"
Inspection Tapping - Top
10
11
12
13
Water Column - Bottom Water Column - Bottom
4"
Boiler Drain
Return
Boiler Drain/Blowoff
Return
4"
Relief Valve
Safety Valve
Relief & Safety Valve Piping
Install the pressure relief or safety valve in the 3" NPT
opening in the top of the back section, Figure 14.
WARNING: The discharge of the pressure relief
or safety valve must be piped close to the floor
to prevent scalding in the event of a discharge,
see Figure 15. The discharge piping must be
sized the same as the pressure relief or safety
valve outlet. Never install any type of valve
between the boiler and the pressure relief or
safety valve! Failure to comply with this
warning can result in an explosion causing
extensive property damage, severe personal
injury or death!
Page 15
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Figure 15 - Relief & Safely Valve Piping
Table 7 - Boiler Water Content
Boiler Model
Water Boilers
Steam Boilers
Gallons Liters Gallons Liters
28A-4
28A-5
28A-6
28A-7
28A-8
28A-9
28A-10
28A-11
28A-12
28A-13
28A-14
28A-15
28A-16
28A-17
28A-18
123
150
177
204
231
258
285
312
339
366
392
419
446
473
500
466
568
670
772
875
104
126
148
170
192
214
236
258
280
302
324
346
368
399
412
394
477
560
644
727
810
893
977
1060
1143
1227
1310
1393
1511
1560
977
1079
1181
1283
1386
1484
1586
1689
1791
1893
Return Piping 10 Through 18 Section Boilers
Install the two 4" NPT x 6" nipples per Figure 16.
Assemble the rest of the return yoke as shown in Figure
16.
Control Installation
Locate the temperature & pressure gage, low water
cutoff, high limit and operating controls per Figures 13
& 7. Optional controls must be installed in accordance
with the control manufacturers instructions and Figures
13 & 17.
WATER BOILER PIPING
The supply and return connections should be sized
to suit the system, see Figures 13, 14, 16, 17 and Tables
5 & 6. Do not pipe the supply from the bottom port or
the return to the top port, the boiler will not work
properly. Typical water boiler piping arrangements are
shown in Figures 18 & 19. Swing joints should be used.
NOTE: The front jacket panel MUST be installed
before any controls are attached to the front boiler
section!
Install 3" nipples into the two 3" NPT tappings in the
front section and cap them.
CAUTION: The controls must be mounted in the
correct location and according to the control
manufacturer’s instructions or the boiler may not
function properly!
NOTE: See CLEANING OF WATER BOILERS on page
18 before proceeding!
Supply Piping
Water Column Piping
Install a reducing bushing in the 6" NPT tapping in the
front section to obtain the correct supply pipe size,
Figure 13 and Tables 5 & 6.
A variety of water level controls are available for the 28A.
The water column piping needed to properly mount each
control is available from Smith. Figure 17 shows a typical
water column piping arrangement. The 1" NPT x 7 1/2"
nipple is always installed in the lower water column
tapping, Figures 13 & 17 and Table 5.
Table 6 - Water Boiler Piping
Boiler Size
# Sections
4 & 5
6 through 9
10 through 18
Return Size
Supply Size
NPT
NPT
3
4
5
3
4
5
Note: Sizes based on 20°F, 11.1°C, ∆T for the system.
Return Piping 4 Through 9 Section Boilers
Install 3" x 4" NPT bushings in the two 4" NPT tappings
at the bottom of the back section. Install the two 3" NPT
x 6" nipples per Figure 16. Assemble the rest of the
return yoke as shown in Figure 16.
Page 16
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Piping For Use With Cooling Units
When a boiler is connected to a heating coil that may
be exposed to refrigerated air from an air handling
device, the piping system must be equipped with flow-
control valves or some other automatic means of
preventing gravity circulation of the boiler water during
the cooling cycle.
The boiler, when used in connection with a refrigeration
system, must be installed so the chilled medium is piped
in parallel with the boiler. Appropriate valves must be
used to prevent the chilled water from entering the
boiler, see Figure 20.
Figure 16 - Optional ReturnYoke
Figure 17 - Boiler Control Locations
STEAM
WATER
Page 17
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Figure 18 -
Typical Single
Water Boiler Piping
Figure 19 - Typical Multiple Water Boiler Piping
Page 18
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
NOTE: Some locations do not allow this solution to
Figure 20 - Chilled Medium Diagram
be used. Check with the local authority having
jurisdiction.
NOTE
FOR HEATING: VALVES “H” OPEN, VALVES “C” CLOSED.
FOR COOLING: VALVES “H” CLOSED, VALVES “C” OPEN.
4. Mix the cleaning chemicals with water to create a
concentrated solution. Pour the cleaning solution
through one of the top tappings in the front section
and plug it.
ROOM
UNIT
EXP. TANK
VENT
5. Immediately fill the rest of the boiler and the heating
system with water.
H
RELIEF
VALVE
6. Fire the boiler and maintain a water temperature
of 160°F to 200°F, 71°C to 93°C it may be
necessary to cycle the boiler.
C
PUMP
DRAIN
FILL
VALVE
7. Run all of the system pumps during the cleaning
procedure.
C
H
DRAIN
CHILLER
BOILER
WARNING: Monitor the boiler pressure
constantly during the cleaning procedure. Do
not allow the boiler pressure to exceed the
pressure listed on the pressure relief valve or a
discharge of hot water and steam will occur!
Cleaning of Water Boilers
Normally the cleaning of water boilers is unnecessary
unless there is unusually heavy contamination of the
boiler or system.
8. Shut the boiler off and allow the boiler to cool to
100°F, 38°C. Open the 3" ball valves and drain the
boiler and heating system.
The burner must be installed and made operational
along with the operating, limit and other safety controls.
The burner on oil boilers must be adjusted to prevent
sooting of the boiler flues.
9. Remove the 3" ball valve and install 3" pipe caps
in the ends of the 3" NPT nipples.
Final burner adjustment should be made after the boiler
has been properly cleaned.
10. Refill the boiler and heating system with water.
WARNING: The pressure relief valve must be
installed and piped to the floor to prevent
scalding in the event of a discharge, see Figure
15.The discharge piping must be sized the same
as the pressure relief valve outlet. Never install
any type of valve between the boiler and the
pressure relief valve! Failure to comply with this
warning can result in an explosion causing
extensive property damage, severe personal
injury or death!
STEAM BOILER PIPING
Steam Boiler Pipeing Connections
Table 3 contains the steam riser location schedule.
Riser, equalizer and header pipe sizes are located in
Table 8. A typical single boiler piping arrangement is
shown in Figure 21. Figures 22 & 23 contain typical
piping diagrams for steam boilers in a battery.
NOTE: See CLEANING OF STEAM BOILERS before
connecting the return piping.
1. Install ball valves on the two 3" NPT nipples in the
bottom of the front section and pipe to a suitable
drain.
CAUTION: Improper placement of steam risers will
result in poor steam quality!
Table 8 - Steam Boiler Piping Sizes
2. Fill the boiler 3/4 full with water.
Boiler
Model
Number of
5" NPT Risers Size, NPT Size, NPT
Header
Equalizer
3. Make a cleaning solution by mixing 1 lb, 0.45 kg
each off caustic soda and trisodium phosphate for
every 50 ga, 189 L of water, see Table 7.
4 & 5
6 & 7
8 Through 10
11 Through 18
1
2
2
3
5"
5"
6"
8"
2 1/2"
2 1/2"
4"
4"
NOTE:The water content of the heating system must
be added to the boiler water content.
The steam piping should be pitched so the condensate
flows in the direction of steam travel. The return tappings
should be yoked to equalize the return flow, Figure 16.
Swing joints should be used.
CAUTION: Avoid skin contact with cleaning solution
to prevent injury! If eye or skin contact occurs flush
with large quantities of water.
Page 19
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Table 9 - Steam Boiler Capacities
Minimum Feed Water
Pumping Rate
Condensate Receiver
Capacity
Gallons
I=B=R Gross Output
Evaporation Rate
Boiler
Model
MBH
900
kW
264
GPM
1.9
2.5
3.1
3.7
4.2
4.8
5.4
5.9
6.5
7.1
7.7
8.2
8.8
9.4
9.9
L/hr
7.3
9.5
GPM
3.9
L/hr
14.8
18.9
23.5
27.6
31.8
36.3
40.5
45.1
49.2
53.8
57.9
62.5
66.6
70.8
75.3
Liters
140
182
223
261
303
345
386
428
469
511
549
591
632
674
716
28A-S-4
28A-S-5
28A-S-6
28A-S-7
28A-S-8
28A-S-9
28A-S-10
28A-S-11
28A-S-12
28A-S-13
28A-S-14
28A-S-15
28A-S-16
28A-S-17
28A-S-18
37
48
59
69
80
1166
1433
1699
1965
2232
2498
2764
3031
3297
3563
3830
4096
4362
4629
342
420
498
576
654
732
810
888
5.0
6.2
7.3
8.4
11.7
13.8
16.0
18.1
20.3
22.5
24.7
26.8
29.0
31.2
33.3
35.5
37.6
9.6
91
10.7
11.9
13.0
14.2
15.3
16.5
17.6
18.7
19.9
102
113
124
135
145
156
167
178
189
966
1044
1122
1200
1278
1356
Note: These recommendations are considered normal for compact buildings. Where buildings are spread out,
additional receiver capacity may be necessary because of the extended time required for condensate to return to
the receiver.
Figure 21 - Typical Single Boiler Steam Piping
Page 20
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Figure 22 - Typical Steam Piping - Gravity Return for Multiple Boilers
Figure 23 - Typical Steam Piping - Pumped Return for Multiple Boilers
Page 21
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Install 3" nipples and ball valves in the two 3" NPT front
section tappings so the boiler can be blown down.
to prevent injury! If eye or skin contact occurs flush
with large quantities of water.
The feed water requirements for steam boilers at full
input are shown in Table 9. The addition of water to the
boiler should be controlled by sensing the actual boiler
water level. 1" NPT water column tappings are provided
on the front section for the mounting of the required
water level controls, see Figure 17.
NOTE: Some locations do not allow this solution to
be used. Check with the local authority having
jurisdiction.
5. Mix the cleaning chemicals with water to create a
concentrated solution. Pour the cleaning solution
through one of the top tappings in the front section
and plug it.
CAUTION: Makeup water connections must be made
to the return piping and not to the boiler or the
boiler may be damaged voiding the warranty!
6. Immediately fire the boiler and maintain a steam
pressure of 0 to 2 psig, 0 to 13.8 kPa. It may be
necessary to cycle the boiler.
Cleaning of Steam Boilers
The burner must be installed and made operational
along with the operating, limit and other safety controls.
The burner on oil boilers must be adjusted to prevent
sooting of the boiler flues. Final burner adjustment
should be made after the boiler has been properly
cleaned.
WARNING: Monitor the boiler pressure
constantly during the cleaning procedure. Do
not allow the boiler pressure to exceed 15 PSI,
103 kPa or a discharge of hot water and steam
will occur!
CAUTION: Failure to properly clean the boiler can
result in foaming and surging and prevent proper
operation of the boiler! Boiler damage can occur
voiding the warranty!
7. Adjust the water feed to prevent the build up of
pressure within the boiler. Continue the skimming
process until the discharge runs clear.
8. Shut the boiler off and allow the boiler to cool to
100°F, 34°C. Remove the skim piping and plug the
tapping. Open the blowdown valve and flush the
boiler until the discharge runs clear.
NOTE: Do not connect the boiler to the return piping
until the system piping has been thoroughly flushed
or recontamination of the boiler can occur.
1. Plug the 4" NPT return tappings in the back section
and any other unused tappings, see step 5 below.
9. Close the blowdown valve and fill the boiler with
water to a level 1in., 25 mm below the normal water
level line.
WARNING: The safety valve must be installed
and piped to the floor to prevent scalding in the
event of a discharge, see Figure 15. The
discharge piping must be sized the same as the
safety valve outlet. Never install any type of
valve between the boiler and the safety valve!
Failure to comply with this warning can result
in an explosion causing extensive property
damage, severe personal injury or death!
10. Check the traps and vents for proper operation.
BURNER INSTALLATION
WARNING: The burner must be installed in
accordance with the burner manufactures
instructions. Check the boiler rating plate to
make sure that the boiler is for the type of fuel
that will be used. If it isn’t, do not connect the
burner to the fuel supply. Failure to comply with
this warning can result in extensive property
damage, severe personal injury or death!
2. Fill the boiler with water to a level 1 in., 25.4 mm
below the normal water level line of 50 1/2 in.,
1.28 m from the floor.
3. Pipe a skimmer off the 6" NPT tapping in the front
section using 1 1/2" NPT pipe.
Follow the burner manufacturer’s installation instructions
for the proper installation, fuel piping, wiring, burner
adjustment and servicing. Mount the burner per the
instructions on page 13.
4. Make a cleaning solution by mixing 1 lb, 0.45 kg
each off caustic soda and trisodium phosphate for
every 50 ga, 189 L of water, see Table 7.
When applicable, provisions for vent, bleed and gas
relief lines must be made in accordance with the latest
revision of ANSI Z223.1/NFPA 54.
CAUTION: Avoid skin contact with cleaning solution
Page 22
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
WARNING: Never use an open flame to test for
gas leaks. Always use an approved leak
detection method. Failure to comply with this
warning can cause extensive property damage,
severe personal injury or death!
Water Boilers
Fill the boiler and all of the radiation with water to the
required system pressure. Completely purge the system
of air and adjust the system pressure as needed.
CAUTION: Thermal shock of water boilers must be
avoided! Water circulation must be established
before the burner is fired. If hot standby is required,
special piping and operation procedures are
necessary, consult your Smith representative.
Failure to protect the boiler from thermal shock can
damage the boiler, voiding the warranty!
Whenever the gas supply piping is pressure tested the
boiler gas controls must be protected. If the test
pressure is equal to, or less than 1/2 psig, 3.5 kPa,
isolate the boiler by closing the manual shut off valve
in the gas supply pipe to the boiler. If the test pressure
is greater than, or equal to 1/2 psig, 3.5 kPa, disconnect
the boiler and its individual shut-off valve from the gas
supply.
Steam Boilers
Fill the boiler with water to the normal water level line
of 50 1/2 in., 1.28 m from the floor.
ELECTRICAL WIRING
Electrical Power Connections
If the boiler is connected to a hot steam line, keep the
cold boiler valved off line and fire the burner until the
boiler pressure exceeds the system pressure by 1 to 2
psig, 7 to 14 kPa. Slowly open the main isolation valve
on the boiler to bring it on line.
CAUTION: Label all wires prior to disconnection
when servicing controls. Wiring errors can cause
improper and dangerous operation! Verify proper
operation after servicing.
CAUTION: Never place a cold boiler into service on
a hot steam line or severe damage to the boiler and
piping can occur voiding the warranty!
The electrical connections to this boiler must be made
in accordance with all applicable local codes and the
latest revision of the National Electrical Code, ANSI/
NFPA-70. Installation should also conform with CSA
C22.1 Canadian Electrical Code Part I if installed in
Canada. Install a separate circuit properly rated for the
boiler. A shut-off switch should be located at the boiler.
Steam entering a cold boiler will cool quickly and can
cause severe steam hammer and boiler flooding. Idle
boilers not valved off from the system should have an
overflow installed to prevent it from being flooded.
The boiler must be grounded in accordance with the
authority having jurisdiction, or if none, the latest revision
of the National Electrical Code, ANSI/NFPA-70.
If an overflow trap is not installed per Figure 24, and
the boiler becomes flooded, the flooded boiler must be
heated to a near steaming condition, 210°F, 99°C, then
drained to the correct water level.
Line voltage field wiring of any controls or other devices
must conform to the temperature limitation of type T wire
at 95°F, 35°C above room temperature. Use copper
conductors with a minimum size of #14 awg.
Water and Steam Boilers
Follow the burner manufactures lighting instructions that
were supplied with the burner.
BOILER OPERATION
WARNING: Never attempt to start the burner if
the combustion chamber contains excess oil or
gas, when the boiler is full of vapor or the
combustion chamber is very hot. Failure to
comply with this warning can result in an
explosion causing extensive property damage,
severe personal injury or death!
WARNING: Before proceeding read and fully
understand the instructions contained in this
manual. Do not attempt to operate this boiler if
it has not been installed in accordance with the
guidelines set forth in this manual. Failure to
comply with this warning can result in extensive
property damage, severe personal injury or
death!
A properly adjusted gas burner on high fire will produce
a CO2 of 8.5 to 9.5% with a CO level under 300 ppm.
When firing on oil at high fire, the burner should be
adjusted to produce a CO2 of 11.0 to 12.0% with a zero
smoke. The flue gas samples should be taken at the
smoke hood. Confirm proper burner adjustment with a
calibrated combustion analyzer.
CAUTION:The supply temperature of a boiler set for
a 20°F, 11°C temperature rise must not be below
140 °F, 60°C for an oil boiler, 149°F, 65°C for a gas
boiler. Failure to protect the boiler from low return
water temperatures will damage the boiler, voiding
the warranty!
Page 23
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Hi Limit
BOILER CHECKING & ADJUSTMENT
The aquastat high limit controls the maximum water
CAUTION: Never increase the input to the boiler
above that for which it is rated. Doing so can cause
premature failure of the boiler!
temperature in the boiler. It is adjustable from 140°F,
60°C to 240°F, 116°C. If the water temperature reaches
the set temperature before the demand for heat has
been met, the aquastat high limit should shut the boiler
off. The water temperature should never exceed the
maximum set point of 240°F, 116°C. The aquastat high
limit cannot be repaired. If it fails to function properly
replace it.
Low Water Cutoff
Ensure that the low water cutoff device(s) function(s)
properly. Test in accordance with the manufacturer’s
instructions included with the device(s).
Figure 24 - Recommended Overflow Trap Piping
Heat Exchanger Cleaning
A flue temperature over 550°F, 288°C, indicates that the
boiler needs to be cleaned.
BOILER MAINTENANCE
WARNING: Servicing, inspection and adjustment
of the boiler must be done by a trained
technician in accordance with all applicable
local and national codes. Improper servicing or
adjustment can result in property damage,
severe personal injury or death!
1. Shut off the electrical power and the fuel supply to
the boiler.
2. Remove the left side jacket panels.
3. Remove the cleanout covers, Figure 7.
4. Clean each flue passage with a wire brush.
The boiler should be cleaned and inspected once a year,
before each heating season.
5. If heavy deposits are present, pull the burner and
vacuum out the combustion chamber.
Page 24
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
6. Vacuum out the burner base and clean and inspect
Controls
all of the components. Replace any damaged or
badly corroded parts.
1. Low water cutoff devices must be serviced per the
manufacture’s instructions.
7. Inspect the cleanout cover insulation and rope seal.
If damaged or deteriorated replace them.
2. The relief valve should vent water when the test
lever is lifted. It should not weep or discharge water
at normal system pressure.
8. Install the clean out covers and reseal them with a
silicone caulk rated for 500°F, 260°C.
WARNING: Never try to clean or repair the relief
valve! If the valve fails to operate properly,
replace it! Failure to comply with this warning
can result in an explosion causing extensive
property damage, severe personal injury or
death!
9. Install the left jacket panels and remount the burner.
10. Restore electrical power and fuel to the boiler.
Vent System
Thoroughly inspect the vent system for any signs of
blockage, corrosion or leakage. Immediately replace any
unsound vent system piping.
3. Use a combustion analyzer to ensure that the
burner is adjusted properly, see BOILER
OPERATION.
Page 25
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Figure 25 - Boiler Assembly
Page 26
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Number of Sections with Item Quantities Below
Ref #
Name of Part
Part #
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1
2
Front Section
3621
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Graphite Port Connector Set
Draw Rod Washers
60375
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17
3
62099 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68
60102 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68
60877 24 32 40 48 56 64 72 80 88 96 104 112 120 128 136
4
5/8" x 11" Draw Rods
5
Draw Rod Hex Nuts
6
8(2)
Rope, 1/2" x 12 1/2 feet
Cleanout Cover Assembly
Cleanout Cover Nut
70660
70592
60245
62095
76538
61414
70614
69371
69372
69373
69904
70633
70611
70612
70613
74301
61997
61998
61999
62000
62002
61983
61984
61985
61986
61987
3630
3
3
6
6
1
6
1
1
4
4
8
8
1
8
1
1
5
5
6
6
7
7
8
8
9
9
10 11 12 13 14 15 16 17
10 11 12 13 14 15 16 17
9
10 12 14 16 18 20 22 24 26 28 30 32 34
10 12 14 16 18 20 22 24 26 28 30 32 34
10
11
12
13
Cleanout Cover Washer
Cleanout Cover Rope Seal, 3/8" x 45"
Cleanout Cover Bolt
1
1
1
1
1
1
1
1
1
1
1
1
1
10 12 14 16 18 20 22 24 26 28 30 32 34
Rear Observation Port Assembly
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
14
15
Slide Damper
1
1
1
1
1
1
1
1
1
1
1
1
Flue Outlet Increaser, 16" to 18"
Smoke Hood Assembly, 10"
Smoke Hood Assembly, 12"
Smoke Hood Assembly, 14"
Smoke Hood Assembly, 16"
Smokehood insulating tape
1
1
1
1
1
1
1
1
1
16(1)
16A
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3/4" Water Relief Valve, 40 lb.
1" Water Relief Valve, 40 lb.
17
18
1 1/4" Water Relief Valve, 40 lb.
1 1/2" Water Relief Valve, 40 lb.
2" Water Relief Valve, 40 lb.
1
1
1
1
1
1
1
1
1
1
1 1/4" Steam Safety Valve, 15 lb.
1 1/2"Steam Safety Valve, 15 lb.
2" Steam Safety Valve, 15 lb.
2 1/2"Steam Safety Valve, 15 lb.
3" Steam Safety Valve, 15 lb.
Back Section
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
19
20
1
Intermediate Section w/ 5" Tapping & Boss
Intermediate Section, Plain with Boss
Intermediate Section, Plain w/o Boss
Int. Section w/ Heater Opening w/o Boss
Hi Limit Control, L4006E
3624
Section quantities based on model ordered
Section quantities based on model ordered
One per water boiler
3622
21
3658
3623
22
23
50507
60327
50653
50655
70628
50510
60267
61931
60317
60326
60318
60314
3420
Tankless Cover Plate & Coil Gasket
Tankless Heater, 8 GPM, 30 L/H
Tankless Heater, 12 GPM, 45 L/H
Tankless Cover Plate with Gasket
Operating Control, L4007A
Quantities based on model ordered
24
25
26
27
28
29
30
31
32
33
Quantities based on model ordered
One per water boiler
3 1/2" Temperature/Pressure Gage
Gauge Glass, 5/8" x 11 1/2"
Observation Glass Gasket, Inner
Observation Glass
One per water boiler
One per steam boiler
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Observation Glass Gasket, Outer
Observation Glass Holder
Observation Glass Cover Plate
(1) Smokehood assembly includes the smokehood, slide damper, angle bracket and hardware.
(2) Cleanout cover assembly includes the cleanout cover, insulation, rope and mounting hardware.
Page 27
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Number of Sections with Item Quantities Below
Ref #
Name of Part
Part #
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
ns
Rear Observation Port Hardware
71301
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Burner Mounting Plate Assembly, 9"
Burner Mounting Plate Assembly, 10 1/4"
Burner Mounting Plate Assembly, 12 1/2"
Burner Mounting Plate Assembly, 10 1/4"
Burner Mounting Plate Assembly, 7 3/4"
Burner Mounting Plate Hardware
70641
70640
70510
70672
70669
71267
69645
34(3)
Burner mounting plate determined by burner selection
ns
35
36
ns
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Burner Mounting Plate Insulating Block
Burner Mounting Plate Rope Seal, 3/8 x 7 ft. 76540
Burner Mtg. Plate Ins. Block Hardware
Operating Control, PA404A
3 1/2" Steam Gage
71268
50493
60269
50494
70492
60090
37
38
39
n/s
n/s
One per steam boiler
One per steam boiler
One per steam boiler
Hi Limit Control, L404C
Can of Spray Adhesive
Flue Brush
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
(3) Burner mounting plate assembly includes the burner mounting plate with the observation glass and cover.
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 RESULT IN
CARBON MONOXIDE POISONING.
EXPOSURE CAN BE FATAL AND EXPOSURE TO HIGH CONCENTRATIONS MAY RESULT IN THE
SUDDEN ONSET OF SYMPTOMS INCLUDING UNCONSCIOUSNESS.
Symptoms of CO poisoning include the following:
dizziness
headaches
nausea
vision problems
loss of muscle control
weakness
shortness of breath
unclear thinking
unconsciousness
The symptoms of CO poisoning are often confused with those of influenza, and the highest incidence of poisoning
occurs at the onset of cold weather or during flu season. A victim may not experience any symptoms, only one
symptom, or a few symptoms. Suspect the presence of carbon monoxide if symptoms tend to disappear when
you leave your home.
The following signs may indicate the presence of carbon monoxide:
• Hot gases from appliance, 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 of CO poisoning occur, or if any of the signs of carbon monoxide are present, VACATE
THE PREMISES IMMEDIATELY AND CONTACT A QUALIFIED HEATING SERVICE COMPANY OR THE GAS
COMPANY OR THE FIRE DEPARTMENT.
To reduce the risk of CO poisoning, have your heating system “tuned up” by a licensed heating contractor or the
gas company -- preferably before each heating season. Also have the service company check your chimney or
vent pipes for blockage.
Your home should also be adequately ventilated, particularly if you have insulated your home.
ONLY QUALIFIED, LICENSED SERVICE CONTRACTORS
SHOULD PERFORM WORK ON YOUR SMITH BOILER.
WARNING
Install, operate and maintain unit in accordance with manufacturer's instructions to avoid exposure to fuel sub-
stances or substances from incomplete combustion which can cause death or serious illness. The State of
California has determined that these substances may cause cancer, birth defects, or other reproductive harm.
Also, install and service this product to avoid exposure to airborne particles of glasswool fibers and/or ceramic
fibers known to the State of California to cause cancer through inhalation.
In an effort to continually improve our products, Smith reserves the right to make changes without notice.
WESTCAST, INC.
260 NORTH ELM STREET WESTFIELD, MA 01085
TEL. (413) 562-9631 FAX (413) 562-3799
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