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 gaskets made from ethylene
propylene, EPT, to seal the section ports. Consult a water treatment professional before
adding any chemicals to the boiler water to ensure that they are compatible with the
gaskets. Failure to comply with this caution can result in failure of the gaskets voiding
the warranty.
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.
A qualified installer, service agency or the gas supplier, must perform installation
and service.
INSTALLER READ THESE INSTRUCTIONS CAREFULLY.
THEY WILL SAVEYOU VALUABLE TIME WHEN ASSEMBLING THE BOILER.
THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER.
CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.
WESTCAST, INC.
260 NORTH ELM STREET WESTFIELD, MA 01085
TEL. (413) 562-9631 FAX (413) 562-3799
Page 3
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
WARNING: Never install a GB300(S,W) boiler on
top of combustible flooring! Failure to comply
with this warning may result in a fire causing
extensive property damage, severe personal
BOILER RATINGS & CAPACITIES
Before undertaking the installation of the GB300(S,W)
boiler check the boiler rating plate to ensure that the boiler
has been sized properly for the job. The rating label has
been packed with the controls.The “Net I=B=R Ratings”
injury or death!
specify the equivalent amount of direct cast iron radiation
4. DO NOT install this boiler in a location that would
that the boiler can supply under normal conditions. Also
subject any of the gas ignition components to direct
ensure that the boiler has been set up for the type of gas
contact with water or excessive moisture during operation
available at the installation site. Other important
or servicing. A full concrete foundation is recommended
considerations are the availability of an adequate
to protect the boiler from moisture and debris, Figure 1.
electrical supply, fresh air for combustion and a suitable
chimney or vent system.
NOTE: The boiler must be assembled on a level, non-
combustible surface. If the floor is not level a pad
must be poured to provide a level surface. If a
concrete block base is used level it using non-
combustible shims or grout.
BOILER LOCATION
1. Locate the boiler in an area that provides good
access to the unit. Servicing may require the removal of
jacket panels. Allow a minimum clearance of 2 ft, 0.61 m
between adjacent construction and the boiler sides and
5. DO NOT place this boiler in a location that would
draft hood. A minimum clearance of 4 ft, 1.22 m must be
restrict the introduction of combustion air into the boiler.
maintained between the front of the boiler and adjacent
construction. Accessibility clearances should take
WARNING: Never store combustible materials,
precedence over fire protection clearances, or use which
gasoline or any product containing flammable
ever is greater.
vapors or liquids in the vicinity of the boiler.
Failure to comply with this warning can result in
2. An optimum site will be level, central to the piping
an explosion or fire causing extensive property
system, close to a chimney and have adequate fresh air
damage, severe personal injury or death!
for combustion.
3. Ensure that the floor is structurally sound and will
support the weight of the boiler. Never install a
GB300(S,W) on a concrete floor that contains wires,
cables, water pipes or hoses. This boiler is designed for
non combustible floors only! Never install this boiler on
combustible materials or carpeting even if a non-
combustible foundation material is placed over them!
Figure 1
Concrete Block Base Construction
Page 4
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Each opening must have a minimum free area of
COMBUSTION AIR & VENTILATION
1 in2/1000 Btu/hr, 2200 mm2/kW based on the total
input rating of ALL gas utilization 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, 300 mm of, but not less than 3 in, 80 mm
from, the top of the enclosure.The bottom opening must
be within 12 in, 300 mm of, but not less than 3 in, 80 mm
from, the bottom of the enclosure.
WARNING: This boiler must be supplied with
combustion 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!
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, 300 mm of, but not less than 3 in, 80 mm
from, the top of the enclosure.The bottom opening must
be within 12 in, 300 mm of, but not less than 3 in, 80 mm
from, the bottom of the enclosure.
WARNING: Never operate a GB300 in an
environment subjected to a negative pressure
unless it is DirectVented. Failure to comply with
this warning can result in excessive levels of
carbon monoxide causing 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, 550 mm2/kW of the total input
rating of all of the equipment in the enclosure.
To operate properly and safely this boiler requires a
continuous supply of air for combustion. Oxygen is used
by the boiler burners to burn the gas. NEVER store
objects on or around the boiler. In addition, air is also
used to assist in the safe disposal of the products of
combustion. This air is known as dilution air and mixes
with the products of combustion to assist in their exit
through the flue pipe and chimney. An adequate supply
of air must be available to replace the air used by these
processes.
Where communicating with the outdoors through
horizontal ducts, each opening shall have a minimum
free area of 1 in2/2000 Btu/hr, 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.
Older buildings often have enough natural infiltration to
provide an adequate amount of combustion air provided
that the demand for combustion air is not too great.
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, 6.4 mm. If the free area through a louver or grill
is not known ducts should be sized per Table 1 below.
Buildings that are relatively new or “tight” will most likely
require the installation of a fresh air duct or other means
of providing make-up air. Any building utilizing other gas
burning appliances, a fireplace, wood stove or any type
of exhaust fan must be checked for adequate combustion
air when all of these devices are in operation at one time.
Sizing of an outside air duct must be done to meet the
requirements of all such devices.
Table 1 Make-up Air Duct Sizing
Required Cross Sectional Duct Area
Input 1/4 in, 6.4 mm
(MBH) Wire Screen
Metal
Louvers
Wooden
Louvers
All Air From Inside The Building
If the boiler is to be located in a confined space
minimum clearances of 2 ft, 0.61 m 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 gas utilization
equipment, fireplaces, wood stoves or any type of
exhaust fan must be considered when making this
determination.
in2
400 100
600 150
800 200
1000 250
1200 300
1400 350
1600 400
1800 450
2000 500
cm2
645
968
1290
1613
1935
2258
2581
2903
3226
in2
cm2
858
1290
1723
in2
cm2
133
200
267
333
400
467
533
600
667
400
600
800
2581
3871
5161
6452
7742
9032
2148 1000
2581 1200
3013 1400
3439 1600 10,323
3871 1800 11,613
4303 2000 12,904
Page 5
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
When more than one appliance is connected to the same
chimney flue the flue must be large enough to safely
CHIMNEY & VENT PIPE CONNECTIONS
vent the combined output of all the appliances.
WARNING: The vent installation must be in
accordance with Part 7,Venting of Equipment, of
the National Fuel Gas Code, ANSI Z223.1/NFPA54-
latest revision or applicable provisions of the
local building codes. Canadian installa-tions
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!
WARNING: If an appliance using any type of a
mechanical draft system operating under
positive pressure is connected to a chimney flue,
never connect any other appliances to this flue.
Doing so can result in the accumulation of
carbon monoxide which can cause severe
personal injury or death!
VENT CONNECTIONS
Chimney Inspection & Sizing
Always use a type B or single wall galvanized metal vent
pipe the same diameter as the draft hood flue collar. Use
the shortest, straightest vent system possible for the
installation. If horizontal runs exceed 6 feet they must
be supported at maximum 6 foot intervals with overhead
hangers. The vent system should be sloped up towards
the chimney at a minimum rate of 1/4 inch/foot and
terminate flush with the inside of the chimney flue.
Fasten each connection with at least 3 corrosion
resistant sheet metal screws.
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
and properly sized.Table 2 lists the equivalent breeching
and flue sizes required for the GB300 boilers.
Table 2 Vent Outlet, Equivalent Breeching
& Chimney Size
Equivalent Breeching
Vent Outlets
& Chimney size
Boiler
Model
Diameter
inches
# of outlets/dia. in inches
WARNING: Never modify or alter any part of the
boiler’s draft hood.This includes the removal or
alteration of any baffles. Never install a vent pipe
of a diameter different than that of the boiler
draft hood flue collar. Failure to comply with this
warning can result in severe personal injury or
death.
mm
254
305
305
356
356
356
381
381
381
406
432
432
432
432
432
GB300-5
GB300-6
GB300-7
GB300-8
GB300-9
GB300-10
GB300-11
GB300-12
GB300-13
GB300-14
GB300-15
GB300-16
GB300-17
GB300-18
GB300-19
1@10
1@12
10
12
12
14
14
14
15
15
15
16
17
17
17
17
17
1@12
2@10
2@10
2@10
2@12
Always provide a minimum clearance of 6 inches between
type C vent pipe and any combustible materials. Type
B1 vent may be used, clearance between it and any
combustible material must be as listed.
2@12
2@12
1@12, 2@10
4@10
4@10
WARNING: Failure to maintain minimum
clearances between vent connectors and any
combustible material can result in a fire causing
extensive property damage, severe personal
injury or death!
4@10
4@10
4@10
NOTE: These sizes are based on a 20 foot chimney height.
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
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.
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.
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. Close
fireplace dampers.
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 fonction-
nent pas: système d'évacuation.
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.
a. Seal any unused openings in the common venting
system.
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.
d. Place in operation the appliance being inspected.
Follow the lighting instructions.Adjust thermostat so
appliance will operate continuously.
Inspecter de façon visuelle le système d'évacu-ation
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.
Mettre l'appareil inspecté en marche. Suivre les
instructions d'allumage. Régler le thermostat de
façon que l'appareil fonctionne de façon continue.
Page 7
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
g. Any improper operation of the common venting
system 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
Part 11 in the National Fuel Gas Code, ANSI Z223.1/
NFPA 54.
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.
Faire fonctionner le brûleur principal pendant 5 min
ensuite, déterminer si le coupe-tirage 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.
Tout mauvais fonctionnement du systéme d'évacu-
tion commun devrait étré corrigé de façor que l'instal-
lation soit conforme au National Fuel Gas Code,
ANSI
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.
Z223.1/NFPA 54 et (ou) aux codes d'installation
CSA-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.
Une fois qu'il a été d éterminé, selon la métode
indiquée ci-dessus, 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.
Figure 2A
Vertical Venting Using A Metal Chimney System And Inside Air(GB300 Series)
2 FT 0.6 m
10 FT 3.4 m
3 FT 0.9 m
3 FT 0.9 m
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
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
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.
Page 11
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
A box with a number from 63265 to 63272, Burner Base
Panels Less Sides, contains the burner base front and
rear panels and the burner base baffle, Figure 4.
BOILER ASSEMBLY
Locate the boiler installation site based on the guidelines
set forth in the previous pages. A full concrete block
foundation is recommended to protect the boiler from
moisture and debris.Use solid blocks to support the boiler
and hollow blocks for the rest, Figure 1. Align the hollow
blocks so air can flow through them.
Figure 4
Burner Base Box 63265 to 63272
WARNING: Never install a GB300(S,W) boiler on
top of combustible flooring! Failure to comply
with this warning may result in a fire causing
property damage, severe personal injury or
death!
Burner Base Assembly General Instructions
WARNING:The burner base must be assembled
as outlined below. Do not make substitutions for
the hardware or materials supplied for the burner
base assemblies. Failure to comply with this
warning may result in property damage, severe
personal injury or death!
The 5/16 stainless steel nuts and bolts used to assemble
the burner base panels are supplied in the X1 box, that
has a number from 72700 to 72707 on it, Figure 5.
Use care not to damage or dislodge the ceramic
insulation board on the base panels during assembly.
Check the contents of the burner base cartons against
the enclosed packing list to ensure that all of the required
parts are present.If they are not, contact your Smith Cast
Iron Boiler distributor or contact the Smith Customer
Service Department.
WARNING: If any of the burner base insulation
panels are broken or damaged they must be
replaced with factory supplied panels. Failure to
comply with this warning may result in property
damage, severe personal injury or death!
The burner base panels are factory insulated to simplify
field assembly of the burner base.
Figure 5
X1 Box 72700 to 72707
Box 63273, Burner Base Side Panels & Brackets,
contains the left & right burner base side panels, manifold
brackets and the jacket brackets, Figure 3.
Figure 3
Burner Base Box 63273
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(s) must
be centered on each piece of refractory board Figure
9B. If the bracket is not centered reposition bracket.
There is (1) bracket for each section of refractory.
Figure 6
Burner Base Side Panels, 5 - 12
Figure 9A
Burner Base Rear Panel, 5 - 12 Sect
Figure 7
Burner Base Front Panel, 5 - 12 Sect
Figure 9B
Refractory Retension Bracket
Page 13
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Burner Base Assembly 13 through 21 Sections
Box 72694, X7 Splice Channels, contains the burner
base front, intermediate and rear channels and
additional 5/16" nuts and bolts, Figure 10.
With the burner base intermediate channel and baffles
level, attach the front and rear channels to the
intermediate channel. Bolt the burner base side panels
to the base baffles, Figure 12.
Figure 10
X7 Box 72694
Figure 12
Burner Base Baffle Front and Rear
Splice Channel Assembly
13 to 21 Sections
The base baffles must be attached to the intermediate
base channel before the side, front and rear panels are
assembled, Figure 11.
Figure 11
Burner Base Baffle and Intermediate
Splice Channel Assembly
13 to 21 Sections
•
Intermediate
Base Baffle
Splice Channel
•
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,Figure 14A. These holes are used to attach
the base rear channel on 6 -12 section rear panels
and 13-21, Figure 14B.
Page 15
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
NOTE:The base front panels bolt to the inside of the
front base splice channel, Figure 15.
Figure 18
Manifold Attachments
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
base rear panel. The notch in the burner must engage
the burner base rear panel, Figure 19.
Use a spirit level to plumb the front and rear panels
before tightening the nuts and bolts, Figure 16.
Temporarily attach the manifold brackets and manifold,
Figures 17 and 18.
Figure 19
Burner Tube Installation
Figure 16
Plumbing Base
Notch
•
Notch
Engaged
•
Figure 17
Manifold Bracket Attachment
Adjust the manifold and base so the burner tube orifice
bracket is approximately in the middle of the orifice on
all three burners, Figure 20.
Figure 20
Burner Tube Adjustment
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 splice refractory and mating base
panels.The retainer should fit snuggly with the flat edge
on the outside of the base and the angled edge mating
flush to the refractory. Once insulation boards are
installed, slide the retention bracket over the top of the
base splice as shown in Figures 22C and 22D.Tighten
all bolts in base.
Figure 21
Burner Base Splice Panel Bracket
Figure 22C
Figure 22D
Figure 22A
Burner Base Splice Insulation Boards
NOTE: Check all of the bolts in the base to ensure
they are tight before removing the burner tubes and
manifold.
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 Section Assembly
WARNING:Never stand the cast iron sections up
without adequate support. They may fall over
resulting in property damage or severe personal
injury!
Clean and inspect each section before assembly. Use a
wire brush and a clean rag to remove rust and debris
from the rope seal grooves and seal ports.
When the second coat of adhesive is tacky place a
strip of ceramic blanket along each side of the base,
Figure 24.
CAUTION: Never use any petroleum-based cleaners
to clean the cast iron sections. Residue from the
cleaner will result in the failure of the hydronic seals!
Figure 24
Ceramic Blanket Placement
Using a tape measure, mark the midpoint of the burner
base on the front and rear panels, Figures 26A and
26B.
Figure 26A
Marking Burner Base Front Midpoint
Lay strips of ceramic blanket along the front and back of
the base making sure to overlap the ends as shown in
Figure 25.
WARNING: The ceramic blanket must be
overlapped as shown in Figure 25 to prevent the
escape of flue gases. Failure to properly seal the
cast iron sections to the boiler base can result
in excessive levels of carbon monoxide which
can result in severe personal injury or death!
-
Page 18
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Figure 26B
Marking Burner Base Rear Midpoint
Figure 28
Figure 29
Figure 30
Ceramic Rope Application
Trimming Ceramic Rope
Casting w/ Ceramic Rope
Apply two coats of the spray adhesive supplied with the
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 Rope Adhesive Application
When the second coat is tacky lay the rope seal into the
three rope groves and press in place. Trim the rope off
flush with the edge of the cast iron section. The rope
seal is to be applied only to one side of each cast iron
section, Figures 28, 29 and 30.
Page 19
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
To ensure that the assembled sections will be centered
on the burner base the cast iron sections should be
assembled from the midpoint of the burner base outward.
Figure 33
Figure 34
Figure 35
Front View - Odd Numbered Models
Rear View - Odd Numbered Models
Section Placement on Burner Base
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 odd number of sections, the
centerline of the first intermediate section should line up
directly with the midpoint marks on the burner base front
and rear panels, Figures 33 and 34.
Refer to Table 3 for the location of the intermediate
sections with steam riser tappings, the flue collector
brackets and the front jacket channel bracket. With the
rope seal in place set the first section on the base making
sure that the section is supported and will not fall over.
The large top port should be above the front of the burner
base, Figure 35.Set the hydronic seals from the X1 Box
in the port openings before carefully bringing the next
section along side of it, Figures 36 and 37.
Figure 31
Front View - Even Numbered Models
Figure 32
Rear View - Even Numbered Models
CAUTION: Do not use adhesives or sealants on the
hydronic gaskets. The application of adhesives or
sealants may result in the failure of the hydronic
seals voiding the warranty!
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
1
2
3
4
5
6
7
8
9
10
11
12
13
LOCATION OF ITEM
- 3" Steam Riser Section Location
FCB - Flue Collector Bracket Section Location
14
15
16
17
18
19
20
21
GB300-5 FCB
GB300-6 FCB
GB300-7 FCB
GB300-8 FCB
GB300-9 FCB
GB300-10 FCB
GB300-11 FCB
GB300-12 FCB
GB300-13 FCB
GB300-14 FCB
GB300-15 FCB
GB300-16 FCB
GB300-17 FCB
GB300-18 FCB
GB300-19 FCB
GB300-20 FCB
GB300-21 FCB
4P
5P
FCB
FCB
6P
7P
FCB
FCB
JSB - Jacket Splice Channel Bracket Section Location
#P - Pilot Burner Tube Location
8P
9P
FCB
FCB
19P
# Represents burner position from LH side of boiler
10P
11P
FCB
20P
FCB
FCB &
JSB
FCB &
JSB
6P
7P
7P
FCB
FCB
26P
FCB &
JSB
FCB &
JSB
22P
23P
FCB
8P
8P
9P
9P
FCB
31P
FCB &
JSB
FCB &
JSB
25P
FCB
FCB
FCB &
JSB
FCB &
JSB
28P
29P
FCB
10P
10P
FCB
FCB &
JSB
FCB
Page 21
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Make sure that the sections are square with the burner
base. Align the bottom front edge of the sections so
they’re flush with the face of the burner base front panel,
Figure 39. Lift the next section into place being careful
not to damage the ceramic blanket or hydronic seals and
install the draw rods, washer and nuts.
Figure 40
Flue Collector Box 63203 to 63210
Use a spirit level to ensure that the first two sections are
plumb, Figure 39.Once plumb, open the Flue Collector
Box. The box will have a number from 63203 to 63210
on it, Figure 40.Remove the flue baffles and install them
as shown in Figure 41. The flue baffles must be
inserted so they’re as high in the openings as
possible. Once all the flue baffles are installed, evenly
torque each washer backed draw rod nut to 30 ft lbs,
42 Nm Figure 42.
WARNING:The flue baffles must be installed as
shown in Figures 40 and 41.The flue baffles must
not be changed or altered in any way. Failure to
comply with this warning can result in excessive
levels of carbon monoxide which can result in
severe personal injury or death!
Figure 41
Flue Baffle Placement
Repeat this process for the remaining sections. Once
the draw rods have been torqued install the four “J” bolts,
washer and nuts from the X1 Box that fasten the heat
exchanger to the burner base, Figure 43.
Figure 39
Confirming Sections Are Plumb
Figure 42
Draw RodTorquing - 30 ft/lbs, 42 Nm
Page 22
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Figure 43
“J” Bolt Installation
Figure 45
Top Jacket Splice Panel Bracket
CAST IRON PRESSURE TEST
NOTE: Before filling the sections with water
temporarily set the flue collector(s) on top of the
sections to locate the flue collector brackets, Figure
44. On 13 to 21 section models attach the top jacket
splice panel bracket, Figure 45. Also mark the
intermediate casting that the flue collectors rest on.
Install a valve in the top and bottom tapping of the left
end section to vent any trapped air and allow boiler
draining after pressure test completion.Connect a water
pressure gage sized for the required test pressure to one
of the end castings. Plug all the other tapped openings.
Fill the cast iron sections with water leaving the top valve
open until all of the air has been bled from the sections.
Figure 44
Flue Collector Bracket Installation
Page 23
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
NOTE: All assembled boiler sections shall pass the
hydrostatic tests prescribed in Section IV of the
ASME Boiler and Pressure Vessel Code.
WARNING: The ceramic blanket must be
overlapped as shown in Figure 47A & B to
prevent the escape of flue gases. Failure to
properly seal the flue collector to the boiler
sections can result in excessive levels of carbon
monoxide which can result in severe personal
injury or death!
CAUTION: Do not connect any boiler controls during
the pressure test or they will be damaged!
Completed boiler blocks must be tested as follows:
Figure 47A
Ceramic Blanket Placement 5-12 Sect.
Steam Boilers - the assembled boiler sections shall be
subjected to a hydrostatic test pressure of not less than
45 psig, 315 kPa.
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.
The hydrostatic pressure shall not exceed the required
test pressure by more than 10 psig, 70 kPa during the
test.
Maintain the test pressure while carefully checking for
leaks. If a leak is found it must be eliminated. Once the
cast iron sections have proven to be watertight drain them
and remove the plugs from any tappings that will be used
in service.
Figure 47B
Ceramic Blanket Placement 13-21 Sect.
FLUE COLLECTOR INSTALLATION
A single draft hood is used on the 5 through 12 section
boilers, two are used on the 13 to 21 section boilers.
The Draft Hood(s) are packed in a box marked with a
number from 63187 to 63194.
Apply two coats of the spray adhesive to the top of the
casings where the flue collectors will rest. When the
second coat of adhesive is tacky place strips of ceramic
blanket on the castings, Figures 46 and 47A & B.
Figure 46
Flue Collector Ceramic Blanket Placement
Page 24
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Position the flue collector(s) on the boiler sections with
Attach the draft hood(s) to the flue collector(s) using the
#10 screws provided, Figure 50. On the 13 through 21
section boilers it will be necessary to lift one draft hood/
flue collector up to install the six screws on the two inner
sides, Figure 51.
the draft hood opening(s) at the rear of the boiler. The
sides of the flue collector(s) should lie along the center
of each end section, Figure 48. Attach the flue collector(s)
to the flue collector mounting brackets using the #10
sheet metal screws supplied, Figure 49.
Figure 48
Flue Collector Placement
Figure 50
Draft Hood Installation
Figure 49
Flue Collector Bracket Installation
Figure 51
Draft Hood Attachment 13 to 21 Sections
Page 25
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Clean Out Covers
Figures 54
Clean Out Cover Bolt Location
The clean out covers and mounting hardware are
packaged in the Burner Box with a number from 72724
to 72731 on it, Figure 52
Figure 52
Clean Out Cover & Hardware
.
Place the foil-backed insulation over the studs with the
foil against the boiler, Figure 55. Install the clean out
cover(s) so the bent edges face out and hand tighten
the wing nuts so the insulation is fully compressed,
Figure 56.
Arrange the clean out cover(s) in front of the boiler so
the mounting stud locations can be determined. Attach
the mounting studs to the heat exchanger as shown in
Figures 53 and 54.
Figure 55
Clean Out Cover Insulation
Figures 53
Clean Out Cover Bolt Assembly
Figure 56
Clean Out Cover Installation
Page 26
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Figure 59
Burner Tube w/ Pilot Bkt. and Pilot
MANIFOLD, BURNER AND PILOT INSTALLATION
Box 63273, Base Panel Sides, contains the manifold
brackets. Bolt the left and right manifold brackets to the
front burner base side panel flanges, Figures 16 and 57.
Figure 57
Manifold Bracket Attachment
Figure 60
1/4" Pilot Tube
Place the manifold on the brackets and bolt it to the
brackets leaving the 5/16 bolts finger tight, Figure 58.
Figure 58
Manifold Installations
Insert the tubing into the brass ferule on the pilot and
tighten it with a wrench, Figure 61. Bend tubing to run
parallel to burner tube exiting front of boiler. Avoid tight
radius.
Figure 61
Burner Tube and Pilot Assembly
The burners are in the Burner Box that has a number
from 72724 to 72731 on it. Locate the burner with the
pilot mounting bracket welded to it, Figure 59.There will
be two burners with pilot mounting brackets for 13 through
21 section boilers.
Attach the pilot(s) to the burner tube(s) using the allen
head screw(s) provided, Figure 59. Remove the roll of
1/4" aluminum tubing and cut an 36" long piece from it,
Figure 60. Ream and clean the tubing so it’s free from
burrs.
Page 27
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Install the supplied 1/8" stainless steel bleed line on
continuous pilot boilers equipped with V88A gas valves.
The bleed line must be located in a fixed position relative
to the pilot burner and allowing for the escaping gases
to be readily ignited by the pilot. Use the supplied
fasteners to connect the bleed line to the valve bleed
orifice and to the pilot-mounting bracket on the burner
tube. Intermittent pilot boilers must vent the V88A bleed
orifice to atmosphere external to the building. The bleed
line and provisions to locate the line are supplied by
the customer. The bleed line on intermittent boilers does
not need to be stainless. Aluminum tubing is
recommended, but all installations must follow local
laws and codes. The burning vent gas must not in any
way affect the pilot flame sensor on the pilot burner.
Follow all applicable local codes.
Pull the tubes forward over the brass orifices in the
manifold engaging the notch in the flattened part of the
burners with rear panel, Figures 63 and 64.
Table 3 has the proper location for the burner tube with
pilot assembly(s).
Figure 63
Burner Tubes on Manifold
Install the burner tubes by sliding the flattened ends
through the slots in the rear panel, Figure 62.
Figure 62
Burner Tube Through Rear Base Panel
Figure 64
BurnerTube LockedTo Rear Base Panel
Page 28
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
When all of the burner tubes are in place adjust the
NOTE:Before installing the jacket, any nipples, steam
risers or short pieces of pipe that will penetrate the
jacket should be installed in the cast iron sections.
Do not attach any fittings or other devices that would
prevent the jacket panels from fitting over them.
manifold so the burner tube orifice brackets are positioned
midway along the cylindrical portion of the orifice, Figure
65. Make sure all of the burner tubes are locked into
the base rear panel as shown in Figure 64.
Figure 65
Burner Tube Placement on Orifice
NOTE:There are two jacket boxes for the 5 through
12 section models.The 13 through 21 section models
will come with 4 jacket boxes.
Open the Box(s) that are marked with a number from
55177 to 55184, Jacket Less Sides, Figure 67, and
remove the jacket rear panel(s).
Figure 67
Box 55177 to 55184, Jacket Less Sides
WARNING: The burner tubes must be installed
as described above. Make sure that the notch
on each burner tube is locked into the rear burner
base panel, Figure 64. Failure to properly install
the burner tubes could result in a fire or
explosion causing extensive property damage,
severe personal injury or death!
JACKET INSTALLATION
Bolt the jacket brackets found in Box 63273 to the lower
rear flange of the burner base side panels, Figure 66.
Figure 66
Rear Jacket Bracket Attachment
Page 29
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
The jacket should be assembled using the black screws
provided. On 5 through 12 section models slide the rear
panel behind the draft hood flanges with the grill side on
the floor, Figures 68, 69 & 70.On 13 to 21 section boilers
open Box 55185, Jacket Splice Box, Figure 71. Screw
the two rear jacket panels to the rear jacket panel splice
panel, Figure 72, before sliding the panels behind the
draft hoods.
Figures 71
Box 72694, Jacket Splice Box
Figures 68
Figures 69
Figures 70
Rear Panel Installation, 5 through 12
Rear Panel Installation, 5 through 12
Rear Jacket Panel Installation Detail
Figures 72
Rear Panel Installation, 13 through 21
Fasten the rear jacket panel(s) to the inner draft hood
and flue collector flanges using the holes provided,
Figure 73.
Figures 73
Rear Panel Installation
Page 30
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Remove the left and right jacket side panels from Box
Figure 76
Jacket Side Panel Installation
55175, Jacket Side Panels. Remove the knockouts
necessary to attach the water or steam piping and
controls.
NOTE: All jacket panel joints must be made so the
panels are metal to metal.The insulation on the edges
of the front, top and rear panels must be pushed
behind the side panel flanges before fastening the
panel together, Figure 74.
Figure 74
Jacket Insulation Detail
Locate the top jacket panel(s), Figure 77.
Figure 77
Top Jacket Panels
Slip the rear flange of one of the side panels between
the rear panel and the jacket-mounting bracket, Figure
75.
Figure 75
Jacket Side Panel Installation
If the removal of knockouts is required to accommodate
any piping they should be removed at this time. Place
the rear top jacket panel on top of the boiler, Figure 78.
On 13 through 21 section boilers two top jacket panels
are required. These panels should be screwed to the
top splice panel before being placed on the boiler,
Figure 79. Make sure that the splice panel flanges are
between the edge of the top panel(s) and the insulation,
Figure 80. Attach the edges of the top jacket panel(s)
so they are metal to metal with the top flanges on both
side panels.
Fasten the side and rear panels together using the bottom
three holes, Figure 76. Align the bottom screw hole with
the hole in the jacket bracket and fasten them to the
bracket. Attach the opposite side panel the same way.
Page 31
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Figure 78
Rear Top Jacket Panel, 5 through 12
Figure 81
FrontTop Jacket Panel, 13 through 21
Figure 79
RearTop Jacket Panel, 13 through 21
Bend the top panel(s) down along the perforation and
attach the front portion of the top to the flange edges
of each side panel, Figure 82.
Figure 82
Front Top Jacket Panel Detail
Install the front jacket top panel(s), Figures 80 and 81.
Figures 80 FrontTop Jacket Panel, 5 through 12
Page 32
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
On 13-21 section models a splice kit is required
Figure 84
Upper Front Splice Panel
to assemble the front jacket panels. The splice kit is
shown in Figure 71. The splice panel sits on the splice
panel brackets shown in Figure 45 and Figure 83.
Figure 84 shows the upper front splice panel in place.
The panels sits on top of the flue collector and is
inserted in the bracket mount. The bottom front splice
panel mounts to the lower bracket and is fastened to
the top splice panel using two jacket screws provided
as shown in Figure 85.
Figure 83
Splice Panel Brackets
Figure 85
Bottom Front Splice Panel
Page 33
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Install the front access panels as shown in Figure 86
5-12 sect and Figure 87 13-21 section using the
supplied screws.
Attach the front grill side panels to the grill top panels as
shown in Figure 88. There are two grill assemblies and
a splice grill for 13-21 section models. Splice grill
assembles exactly like the full size grill panels Figure
89 The splice grill must be inserted in the middle of the
boiler in line with the jacket splice panel. Install grill(s)
over manifold and burners, Figure 90.
Figure 86
Front Access Panel 5 - 12 Sect
Figure 88
Grill Assembly
Figure 89
Splice Grill Assembly
Figure 87
Front Access Panel 13 - 21 Sect
Figure 90
Installed Grill
Page 34
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Gas Train Assemblies
All threaded gas train connections must be made using
Pilot Assembly
a pipe compound that is resistant to the actions of
liquefied petroleum gases. Pipe connections should be
secure and tested for leaks. This boiler is designed to
allow for the installation of the gas train on either the
left or right side of the boiler. Locate the gas train in the
most ideal location, but ensure that the train and controls
are protected from water and other possible damage.
Install the supplied pipe cap on the manifold end
opposite the location of the gas train. Install the supplied
reducer coupling to the manifold where the gas train will
be located.
The pilot assembly must be performed after the
installation of the control box.
The pilot assemblies are fed gas through 1/4" aluminum
tubing. The tubing is supplied in a bulk roll and must be
cut to fit in the field. Use an appropriate tubing cutter to
cut the rolls to length. Debur and clean all cuts to ensure
a clean line without blockage or interference. Use a
tubing bender to bend the tube and the supplied tubing
clamps to fasten it to the boiler jacket. Figure 92 and
Figure 93 show a recommended layout of the pilot
tubing. The gas train instruction manual shows the
component layout and how the fittings are arranged on
the purchased gas train page.
Refer to the Gas Train Assembly Instructions for a
detailed diagram of how the fittings should be arranged
and assembled. The instructions are arranged by gas
train assemblies. Look up the purchased gas train and
confirm all parts for that train are accounted for.
Assemble the train as depicted in the instructions. Refer
to the GAS SUPPLY PIPING section of this manual to
make the final connection to the main gas supply.
Figure 92
Single Pilot Tubing Run 5 - 12 Sect
For installations in Canada a manual shutoff valve must
be installed between the manifold and the first gas valve.
On gas trains with two valves the V88A valve must be
installed first (closest to supply), followed by the regulating
valve closest to manifold, Figure 91. Refer to diagrams
in gas train assembly book.
Figure 91
Gas Train,Valve Orientation
Figure 93
Double Pilot Tubing Run 13 - 21 Sect
For installations in Canada a manual shutoff valve must
be installed between the pilots.
The pilot tubing runs must be done in a neat, workman
like manner.Use the provided tubing clamps and screws
to attach the pilot tubing to the jacket as required.
Page 35
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Figure 94
Water & Steam Control Tapings
HEATING SYSTEM PIPING
3
NOTE: The boiler jacket must be installed before
connecting the heating system piping and controls.
6
5
4
1
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, and ANSI/ASME CSD-1, Standard for Controls and
Safety Devices for Automatically Fired Boilers. 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.
7
6
8
8
8
2
Tapping
Size
4"
Water
Supply & Optional
Tankless Heater
Steam
Optional Safty Valve
Location &
CAUTION: Improper piping of this boiler can cause
flooding and extensive property damage!
1
Skim Tapping
Return & Boiler
Drain/Blowoff
Steam Relief Valve &
Optional Control
Tree Location
N/A
2
3
3"
Return & Boiler
Drain/Blowoff
Water Relief Valve
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.
1-1/2"
4
5
6
3/4"
3/4"
3/4"
Temp./Pressure Gauge2
High Limit2
Operating Control2
Gauge Glass3
Control Tree
If a boiler is installed above any radiation elements it
must be fitted with a low water cutoff device.
(see Figure 99)
Optional Probe
LWCO3
Optional Float
LWCO’s3
7
8
3/4"
1"
Optional Probe
WATER BOILER PIPING CONNECTIONS
LWCO
Optional Float
LWCO’s
The supply and return connections should be sized to
suit the system, see Figure 94 & Table 4. Do not pipe
the supply from the bottom port or the return to the top
port, the boiler will not work properly.
Notes:
1. The left end section contains the same tappings as the right end
section.
2. These controls must be located on the supply piping side of the
boiler.
3. These controls must be located on the steam equalizer piping
side of the boiler.
Page 36
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Table 4
Supply & Return Pipe Sizing
Piping For Use With Cooling Units
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.
Boiler Model
5 - 10 section
11 - 21 section
Supply Size (in) Return Size (in)
3"
4"
3"
3"
Install the Pressure Relief Valve in the 1 1/2 NPT
opening in the top of the end section opposite the gas
controls. Pipe the discharge of the Pressure Relief Valve
to prevent scalding in the event of a discharge, see
Figure 93. The discharge piping must be sized the same
as the Pressure Relief Valve outlet.
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.
CAUTION: If the relief valve must be installed on the
same end as the gas controls, provisions to protect
the controls from water in the event of a discharge
must be made.
Steam Boiler Piping Connections
Table 3, contains the steam riser location schedule.Riser,
equalizer and header pipe sizes are located in Table 5.
A typical single boiler piping arrangement is shown in
Figure 95. Figures 97 & 97A contain typical piping
diagrams for steam boilers in battery. The steam piping
should be pitched so the condensate flows in the direction
of steam travel.
Locate the Theraltemeter, Low Water Cutoff Device, Hi
Limit Control and Operating Control per Figures 94 & 95.
Optional controls must be installed in accordance with the
control manufacturers instructions and Figure 94.
Figure 95
Single Water Boiler Piping
ASME
Safety
Valve
Hi Limit
Control
Temperature
Pressure Gage
Operating
Control
Page 37
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Figure 97
Water Boilers in Battery
Preferred Location
Of Circulating Pump
ASME
Safety
Valve
Expansion Tank
External
Low-water
Cutoff
Expansion Tank
ASME
Safety
Valve
Pressure
Reducing
Valve
Maximum
Temperature
Limit Control
Hi Limit
Control
Hi Limit
Control
Temperature
Pressure Gage
Blowoff
Valves
Stop
Valve
Maximum
Temperature
Limit Control
Hi Limit
Control
Blowoff
Valve
Internal
Low-water
Cutoff
Temperature
Pressure Gage
Check Valve
Air Vent
Check
Valve
Stop
Valve
Alternate Arrangement
With Diaphragm Expansion
Tank (Required On Each
Boiler)
Figure 97A
Typical Single Boiler Steam Piping
Stop Valve
Steam Main
Pres.
Controls
ASME
Safety
Valve
F & T
Trap
LWCO
Steam Gage
Gage Glass
Stop Valve
Check Valve
Blowoff
Valve
Page 38
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Figure 98
Typical Steam Piping - Gravity Return for Multiple Boilers
Stop Valve
ASME
Safety
Valve
Stop Valve
To Return
Header
F & T
Trap
Pres.
Controls
ASME
Safety
Valve
Steam Gage
LWCO
& Gage
Glass
Stop Valve
Check Valve
Water Column
& Gage Glass
Blowoff Valves
Check Valve
Stop Valve
LWCO
Press.
Controls
Steam
Gage
Blowoff Valves
Figure 98A
Typical Steam Piping - Pumped Return for Multiple Boilers
Stop Valve
ASME
Safety
Valve
Stop Valve
F & T Trap
High Level
“Spill”
ASME
Safety
Valve
To Receiver
Tank
LWCO
Pump
Control
& Gage
Glass
Pres.
Controls
Pres.
Controls
Steam Gage
Stop Valve
To Receiver
Tank
F & T Trap
High Level
“Spill”
Check Valve
Pump Control
& Gage Glass
Blowoff Valves
LWCO
Solenoid Valve
Stop Valve
Check Valve
Steam
Gage
Solenoid Valve
Page 39
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
CAUTION:Make up water connections must be made
to the return piping, not directly to the boiler or boiler
damage may result.
Table 6 should be used to ensure that the gas supply
piping is sized properly. If more than one appliance is
supplied by the same supply pipe, the piping must be
sized based on the maximum possible demand. Do not
neglect the pressure drop due to pipe fittings. Table 6
should be used in conjunction with Table 7 to ensure
that the supply piping has the capacity to meet the
demand.
Locate the boiler blow off preferably opposite the return
piping connections. Blow off valves must be sized equal
to, or larger than, the steam relief valve. Any discharge
piping is to be full size to the point of discharge.
Assemble the control tree and low water cutoff as shown
in Figure 99. Use Figure 94 to locate the control tree
and low water cutoff on the boiler.
Table 6
Gas Pipe Capacity
Maximum pipe capacity in ft3/hr based on 0.60 specific gravity gas
at a pressure of 0.5 psig or less and a 0.3" WC pressure drop.
Nominal
Iron Pipe 10
Size, (in)
1"
1-1/4"
1-1/2"
2"
2 1/2"
3"
Pipe length in feet
40 50 60
Maximum gas volume of pipe, (ft3/hr)
20
30
80 100 150
Table 5
Boiler Model
GB300-5 to -9
GB300-10 to -15 2 @ 3"
GB300-16 to -21 3 @ 3"
Riser, Equalizer & Header Pipe Sizes
Risers
Equalizer Header
520 350 285 245 215 195 170 150 120
1050 730 590 500 440 400 350 305 250
1600 1100 890 760 670 610 530 460 380
3050 2100 1650 1450 1270 1150 990 870 710
4800 3300 2700 2300 2000 1850 1600 1400 1130
8500 5900 4700 4100 3600 3250 2800 2500 2000
1 @ 3"
1-1/2"
2"
3"
3"
4"
5"
Figure 99
Steam Control Tree
Note:
Multiply the gas volume by 0.62 for propane flow capacity in ft3/hr.
Multiply the propane flow capacity by 2500 Btu/ft3 to determine the
propane Btu/hr capacity for a given pipe size and length.
STEAM
GAUGE
MANUAL RESET
HIGH LIMIT
Table 7
Equivalent Pipe Length Chart
PET COCK
SYPHON
OPERATIG
CONTROL
Nominal
Type of pipe fitting
Iron Pipe
Size, (in)
1"
1-1/4"
1-1/2"
2"
90 Elbow
Tee1
Gate Valve2 Gas Cock2
Equivalent pipe length, (ft)
2.6
3.5
4.0
5.2
6.2
5.2
6.9
8.0
10.3
12.3
0.6
0.8
0.9
1.2
1.4
1.5
1.9
2.3
3.0
3.7
SYPHON
2-1/2"
3"
7.7
15.3
1.8
4.5
Notes: 1. For flow through branch.
2. For flow at full open.
GAUGE
GLASS
L.W.C.O.
(OPT.)
Figure 100 depicts the proper way to connect the boiler
to the gas supply piping. The manual shut-off valve
MUST be installed in the supply piping. It should be
approximately 5 feet above the floor. Provide a sediment
trap at the bottom of the vertical section of the gas
supply pipe upstream of the gas controls. A ground joint
union should be installed between the boiler gas
controls and the supply piping. Each of these items are
needed to ensure long life and ease of servicing.
Always use a pipe sealant that is suitable for use with
LP gas.
GAS SUPPLY PIPING
WARNING: Check the boiler rating plate to make
sure that the boiler is for the type of gas that will
be used. If it isn’t, do not connect the boiler to
the gas supply. Failure to comply with this
warning can result in extensive property damage,
severe personal injury or death!
CAUTION: Always use a wrench on the gas valve
body when making gas connections to it. Never over-
tighten the piping entering the gas valve body or gas
valve failure may result!
The GB300(S,W) boiler comes from the factory ready to
be piped to the gas supply. If for any reason the boiler is
not for the type of gas available at the installation site,
call the nearest Smith Cast Iron Boiler distributor to
resolve the problem.
Page 40
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Figure 100
Gas Supply Piping
ELECTRICAL WIRING
TO GAS SUPPLY
Electrical Power Connections
PILOT SHUTOFF VALVE
MANUAL
SHUTOFF
VALVE
GAS PRESSURE
TEST TAPPING
CAUTION: Label all wires prior to disconnection
when servicing controls. Wiring errors can cause
improper and dangerous operation! Verify proper
operation after servicing.
PILOT FILTER
PILOT GAS PRESSURE
REGGULATOR
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 120 volt 15 amp circuit for
the boiler. A shut-off switch should be located at the
boiler. 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.
TO PILOT(S)
GROUND
INSTALL MANUAL
SHUTOFF VALVE
5FT. ABOVE FLOOR
WHERE REQUIRED
BY LOCAL CODES.
JOINT
UNION
TO GAS
CONTROL(S)
SEDIMENT TRAP & DRIP LEG
( TO EXTEND TO FLOOR )
Line voltage field wiring of any controls or other devices
must conform to the temperature limitation of typeT wire
at 95°F(35°C) above room temperature. Use copper
conductors with a minimum size of #14 awg.
When applicable, provisions for vent, bleed and gas
relief lines must be made in accordance with the latest
revision of ANSI Z223.1.
The incoming line voltage is connected to the boiler using
the supplied junction box and transformer.All high voltage
connections must be contained inside the junction box
leaving only 24 volt termination exposed. The junction
box MUST be located on the side were the boiler controls
are located and on the jacket panel in the upper right
hand corner (1/2" max from the top and 1/2" max from
the front side of the jacket panel). Failure to mount the
junction box and transformer in this area will cause wire
harness length to not be of the proper size, resulting in
the inability to connect the termination points and
harnesses together. See Figure 101 Transformer
Location.
Safe lighting and other performance criteria were met
with the gas manifold and control assembly provided on
the boiler. All gas connections MUST be leak tested
before putting the boiler into operation.
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!
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 it's manual shut off valve. 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.
Figure 101
Transformer Location
Page 41
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Use the factory supplied wiring schematic booklet to
connect power to the boiler.The schematic booklet also
BOILER OPERATION
depicts how to interconnect the boiler controls, using the
supplied wire harness.Before connecting any harnesses,
the control panel and wire duct must be attached to the
boiler using the supplied fasteners.There are prepunched
holes in the jacket panel to help locate and install these
components. Use as many fasteners as required to
secure control panel and wire duct to front jacket panel.
Prepunched holes are for locating purposes only and
may not securely fasten components. Run the wire
harnesses inside the plastic wire duct between
termination points, see Figure 102. Instructions for
cutting, locating and mounting the wire duct can be found
in the electrical book. The wire harnesses' identification
and mounting location information can also be found in
the electrical wiring diagram book.
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!
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.
Steam Boilers
Fill the boiler with water to a level 1" below the normal
water level line of 33 1/4". Clean the newly installed
sections as outlined below:
Figure 102
Wire Duct and Control Box
CAUTION: Do NOT use any petroleum based
cleaners to clean the boiler or the hydronic seals will
be damaged!
1. Pipe the skimmer tapping on the front of one of the
end sections to a floor drain using 1 1/2" pipe.
2. Adjust the boiler water level until water begins to
flow out of the skim piping at a slow rate.
3. Fire the boiler and maintain a water temperature of
180°F to 200°F. It may be necessary to cycle the boiler.
Thermostat Installation
4. Adjust the water feed to prevent the build up of
pressure within the boiler.Continue the skimming process
until the discharge runs clear.
If a thermostat is to be used to control the boiler always
follow the instructions included with the thermostat.
Proper location of the thermostat will ensure efficient
trouble-free operation of the boiler.Mount the thermostat
to an inside wall at a height approximately five feet above
the floor. Avoid placing the thermostat in areas that will
not provide an accurate measurement of the room
temperature. Locating the thermostat behind a door, in
an alcove, close to a source of thermal radiation or in a
drafty area will cause poor or sporadic heating.
5. Shut the boiler off and allow the boiler to cool to
100°F. Remove the skim piping and plug the tapping.
Open the blowdown valve and flush the boiler until the
discharge runs clear.
6. Close the blowdown valve and fill the boiler with
water to a level 1" below the normal water level line.
7. Check the traps and vents for proper operation.
Page 42
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
10. Push and hold down the red button on the pilotstat.
LIGHTING INSTRUCTIONS
Light the pilot with a match and wait approximately one
(1) minute before releasing the button.The button should
pop back and the pilot(s) remain lit. For two pilot systems
repeat this procedure for the other pilot. If a pilot will not
stay lit after several tries, adjust pilot reg to higher
pressure. Turn reg clockwise to increase and
countercloskwise to decrease pressure. If pilot still fails
to light, close the manual pilot valve and call your service
technician or gas supplier.
A. If this appliance is equipped with a continuous pilot
it must be lit by hand. Follow the lighting instructions
exactly when lighting the pilot. If this appliance is
equipped with an intermittent pilot, the ignition control
will automatically light the pilot. Follow the operating
instructions and do not try to light the pilot or burner
by hand.
B. BEFORE LIGHTING smell all around the appliance
area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.
11. With the pilot(s) lit, turn on all electric power to the
appliance.
C. Do not use this appliance if any part has been under
water. Immediately call a qualified service technician to
inspect the appliance and to replace any part of the
control system and any gas control which has been
under water.
12. Open the manual main gas shut-off valve.
13. Set the operating control so there's a call for heat.
14. The burners should light with proper boiler operation.
CAUTION: To prevent being burned, stand clear of
the boiler during ignition and don't touch any hot
metal parts.
15. A boiler designed for use with natural gas should
have a manifold gas pressure of 3.5" WC on High Fire
and 0.8" WC on Low Fire for 2 stage units. On an LP
boiler, the manifold pressure should be 10" WC on
highfire, 2 stage firing not avaialble on LP models. To
adjust the manifold gas pressure see the GAS
PRESSURE ADJUST-MENT instructions in the BOILER
CHECKING & ADJUSTMENT section.
Continuous Pilot Systems
1. STOP! Read the safety information above. If, at any
time, the boiler will not operate properly, follow the
instructions “TO TURN OFF GAS TO BOILER” and call
your service technician or gas supplier.
16. Test the ignition safety shutoff device. Close the
manual pilot valve. Within three minutes the pilotstat
should close de-energizing the main gas valve(s).
Repeat steps 9 through 14. Disconnect the thermo-
couple from the pilotstat, the main burners should go
out. Extinguish the pilot and reconnect the thermo-
couple. There should be NO gas flow to the main
burners with the pilot out! If gas flow is detected,
immediately turn the main manual shut-off valve off and
have the problem corrected.
2. Set the operating control to off or its lowest setting.
3. Turn off all electric power to the boiler.
4. Close the manual main and pilot gas shut-off valves.
5. Wait five (5) minutes** to clear out any gas. Then
smell for gas, including near the floor. If you smell gas,
STOP! Follow “B” in the safety information above (to the
left) on the label. If you don’t smell gas, go to the next
step.
Intermittent Pilot Ignition Systems
1. STOP! Read the safety information above. If, at any
time, the boiler will not operate properly, follow the
instructions “TO TURN OFF GAS TO BOILER” and call
your service technician or gas supplier.
6. Remove the front grill(s).
7. Connect a manometer having a minimum capacity
of 20" WC to the outlet pressure port of the gas valve.
Make sure that the gas supply piping has been purged
of air and that all gas joints up to the manifold have been
thoroughly checked for leaks.
2. Set the operating control to off or its lowest setting.
3. Turn off all electric power to the boiler.
8. Locate the pilot(s).
4. Close the manual main and pilot gas shut-off valves.
9. Open the petcock pilot valve.
5. Wait five (5) minutes** to clear out any gas. Then
smell for gas, including near the floor. If you smell gas,
STOP! Follow “B” in the safety information above (to the
left) on the label. If you don’t smell gas, go to the next
step.
Page 43
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
6. Remove the front grill(s).
To Turn Off Gas To Boiler
1. Set the operating control to its lowest setting.
7. Connect a manometer having a minimum capacity
of 20" WC to the outlet pressure port of the gas valve.
Make sure that the gas supply piping has been purged
of air and that all gas joints up to the gas valve have
been thoroughly checked for leaks.
2. Turn off all electric power to the appliance if service
is to be performed.
3. Close the manual main and pilot gas shut-off valves.
8. Open the petcock pilot valve.
BOILER CHECKING & ADJUSTMENT
PILOT ADJUSTMENT
The pilot burner flame should envelope 3/8" to 1/2" of
the thermocouple tip or flame-sensing probe, depending
on the pilot type.Figure 103 depicts an intermittent pilot,
but the adjustment dimensions for a continuous pilot
would be the same.To adjust the pilot the following steps
must be taken:
9. Turn on all electric power to the boiler.
10. Set the operating control to the desired setting.
11. The pilot(s) should automatically light. Do not try to
light the pilot(s) by hand!
12. With the pilot(s) lit, open the main gas shut-off valve.
13. The burners should light with proper boiler operation.
1. Remove the cap next to the pilot tube fitting on the
gas valve or on the separate pilot gas regulator where
one is used.
14. A boiler designed for use with natural gas should
have a manifold gas pressure of approximately 3.5" WC
on high fire and 0.8" WC on low fire. For an LP boiler,
the manifold pressure should be 10" WC. To adjust the
manifold gas pressure see the GAS PRESSURE
ADJUSTMENT instructions in the BOILER CHECKING
AND ADJUSTMENT section.
2. Turn the pilot adjustment screw on the valve
counterclockwise to increase the flame, clockwise to
decrease it. On the separate pilot gas regulator turn the
regulator screw clockwise to increase the flame,
counterclockwise to decrease it.
3. Replace the pilot adjustment screw cap.
15. With the burners in operation, close the manual
shutoff valve in the gas supply line. As soon as the main
burner flames go out, open the manual shutoff valve. A
normal ignition sequence should take place. If the
burners fail to light the system will make two more
ignition attempts. If the burners have not lit after the last
ignition try, the gas valve will close and the system will
go into lock out. DO NOT attempt to reset the system
until the ignition system has been inspected and the
problem resolved.
Figure 103
Pilot Flame Adjustment
SCREWS
BRASS FERULE
1/4" TUBING
With the burners in operation, interrupt the power to the
control circuit by lowering the operating control.The main
burners should go out. Reset the operating control, a
normal ignition sequence should follow.
Gas Pressure Adjustment
To test the ignition safety shutoff device, close the
manual shutoff valve in the gas supply line. Within 6
seconds of main burner flame extinction, the main gas
valve solenoid should close with an audible noise.
NATURAL GAS: Optimum results are obtained when
the boiler is operated at its full input rating, with 3.3"WC
to 3.7" WC and 1.0" to 0.8" on low fire of manifold
pressure.The manifold pressure should not vary outside
this range. The gas valve pressure regulator has been
preset at the factory. If adjustment is necessary the
following steps must be followed:
A sparking noise should be heard while the ignition
module tries to light the pilot. After 1 minute the module
should lockout and the try for ignition end. Open the
manual shutoff valve in the gas supply line and reset the
ignition control system. A normal ignition sequence
should take place.
NOTE: The Honeywell VR8404 valve is factory set
and cannot be field adjusted
Page 44
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
1. Attach a 20" manometer to the tap on the manifold.
DO NOT adjust the manifold pressure by more than 5%.
If a proper rate cannot be maintained without adjusting
the manifold pressure beyond the 5% limit, the main
burner orifices must be replaced. If the input rate is too
low, go to the next lager size main burner orifices. If the
input rate is too high, go to the next smaller size.
2. Remove the regulator adjustment screw cap from
the gas regulator. On systems that do not use a
separate gas regulator, remove the adjustment screw
cap from the gas valve body on the valve closest to the
gas supply piping.
CAUTION: Never increase the input to the boiler
above that for which it is rated. Doing so can cause
premature failure of the boiler!
3. Rotate the regulator adjustment screw clockwise to
increase the manifold pressure, counterclockwise to
decrease it.
Low Water Cutoff
4. Replace the regulator adjustment screw cap and
pressure tap plug.
Ensure that the low water cutoff device(s) function
properly. Test in accordance with the manufacturer’s
instructions included with the device(s).
CAUTION: Never force the regulator adjustment
screw beyond the stop limits or damage to the
regulator will occur!
Thermostat Adjustment
For a thermostat that employs an adjustable heat
anticipator, adjust the anticipator to match the current
measured in the thermostat circuit. An increased
anticipator setting may be necessary if the unit cycles
frequently. If the room temperature over-shoots the
thermostat setting, reduce the anticipator setting.
PROPANE GAS:A manifold pressure of 10"WC must
be maintained for proper operation of the boiler. If the
manifold pressure is off by more than 5% adjust it
according to steps 1 through 4 above.
Input Rate
Gas appliances are rated based on sea level operation
with no adjustment required at elevations up to 2000 feet.
At elevations above 2000 feet, input ratings should be
reduced by 4% for each 1000 feet above sea level.
BOILER MAINTENANCE
CAUTION: Servicing, inspection and adjustment
must be done by a trained technician in accordance
with all applicable local and national codes. Improper
servicing or adjustment can damage the boiler!
Check the input rate as follows:
1. Turn off all other gas appliances that use the same
gas meter as the boiler.
The boiler should be cleaned and inspected once a year,
before each heating season. Make sure that the
burners and ignition components are free from dust,
soot, dirt, corrosion or other deposits that would impair
the boiler’s performance.
2. Call your gas supplier and ask for the heating value
of the gas.
3. Start the boiler and let it run for 15 minutes.
Burner Removal
1. Close the manual shutoff valves in the gas supply
lines and turn off electrical power to the boiler.
4. Using the gas meter and a stop watch, clock the
time that it takes to burn 10 cubic foot of gas and divide
this time by 10.
2. Remove the front grill(s).
5. Insert the heating value and the time, in seconds,
into the formula below.
Input = (heating value, Btu/hr)(3600)/(time, seconds)
3. Lift the rear of the burner up and slide it towards
the back of the boiler. When the orifice bracket is clear
of the orifice lower the burner and remove it by sliding
it forward and out from the boiler.
If the computed rate deviates by more than 5% from the
rated input value of the unit adjust the manifold pressure
accordingly.
4. Inspect each burner for damage or signs of
deterioration. Use a brush or compressed air to remove
any debris from the burner ports.
NOTE:The HoneywellVR8404 valve is factory set and
can-not be field adjusted
Page 45
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
3. The relief valve should vent water when the test lever
is lifted. It should not weep or discharge water at normal
system pressure. NEVER try to clean or repair the relief
valve! If the valve fails to operate properly, replace it!
Burner Installation
1. DO NOT install damaged or badly corroded burners,
replace them.
2. Install the burners by sliding the rear of the burner
tube into the slot located in the base rear panel. Slide
the burner into the slot far enough so that the burner
bracket clears the orifice on the manifold. Pull the burner
back onto the orifice making sure that the notch in the
crimped portion of the burners engages the rear burner
base panel locking it into place.
4. The aquastat high limit controls the maximum water
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 (60°C). The aquastat
high limit cannot be repaired. If it fails to function
properly replace it.
3. Replace the front grill(s).
Heat Exchanger Cleaning
5. Visually check the pilot and main burner flames to
ensure proper operation, see Figure 103 & 104.
The burners should be removed to protect them from
falling rust and scale. Follow the BURNER REMOVAL
instructions in this manual.
WARNING:Yellow, floating flames indicate a lack
of combustion air. Do not operate the boiler until
the problem is solved or severe personal injury
or death may occur!
1. Remove the front grill(s) and front access panel(s).
2. Remove the clean out covers and insulation, Figure
55 & 56.
Figure 104
Main Burner Flames
3. Clean each flue passage with a wire brush.
4. Vacuum out the burner base and clean and inspect
all of the components. Replace any damaged or badly
corroded parts.
5. Replace the insulation and clean out covers,
6. Replace the front access panel.
NORMAL
(HARD FLAME)
LIFTING
(TOO MUCH AIR)
7. Install the burners following the BURNER
INSTALLATION procedure outlined in this section.
8. Replace the front grill(s).
Vent System
Thoroughly inspect the vent system for any signs of
blockage, corrosion or leakage.Immediately replace any
unsound vent system piping.
YELLOW TIPPING
(MARGINAL)
YELLOW FLAME
(TOO LITTLE AIR)
Controls
Use the BOILER OPERATION and BOILER CHECKING
AND ADJUSTMENT sections of this manual for
reference.
1. Check the thermostat or operating controls for
proper operation.
2. A float type low water cutoff device must be flushed
out.
Page 46
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
6
56
55
58
59
54
10
46
6
45
44
42
38
50
53
39
40
52
41
37
27
49
48
14
28
13
29
12
15
Page 47
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Number of Sections with Item Quantities Below
Ref # Name of Part
Part #
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21
—
Jacket Less Sides Panels
55177
1
55178
55179
55180
55181
55182
55183
55184
55176
55185
1
2
1
1
1
2
1
1
1
2
1
1
1
1
2
1
1
1
1
2
1
1
1
1
—
—
Jacket Side Panels, Left & Right
Jacket Splice Panels, Front, Top,
Rear & Grill
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
—
6
Jacket Screws
60442 32 32 32 32 32 32 32 32 62 62 62 62 62 62 62 62 62
Flue Collector
63203
63204
63205
63206
63207
63208
63209
63210
63187
63188
63189
63190
63191
63192
63193
63194
1
1
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
2
1
10
Draft Hood
1
1
2
1
1
1
2
1
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
2
1
1
1
—
Flue Collector & Draft Hood Hardware 72715
1
1
1
1
1
1
1
1
1
Page 48
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Number of Sections with Item Quantities Below
Ref # Name of Part
Part #
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21
12
Manifold Less Orifices
63243
1
63244
63245
63246
63247
63248
63249
63250
63253
63254
63255
63256
63257
63258
63259
63260
63261
60093
60242
63251
63262
63282
63283
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
13
14
Orifices, Natural Gas
8
8
7
1
7
1
1
1
10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
Orifices, LP Gas
Burner Tubes Less Pilot Bracket w/Shutter NG
Burner Tubes w/Pilot Bracket w/Shutter NG
Burner Tubes Less Pilot Bracket LP
Burner Tubes w/Pilot Bracket LP
9
1
9
1
1
1
11 13 15 17 19 21 22 24 26 28 30 32 34 36 38
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
11 13 15 17 19 21 22 24 26 28 30 32 34 36 38
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
15
Robertshaw 7000 DERHC, Natural Gas, 1" 51186
Robertshaw LP Conversion Kit
51083
72733
Honeywell V88A-1618, Natural Gas, 1"
1
1
1
1
1
1
1
1
1
1
Honeywell V8943B-1010, Natural Gas, 1" 50169
Honeywell V88A-1618, LP Gas, 1" 72733
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Honeywell V8943C-1018, LP Gas, 1" 50174
Honeywell V88A-1626, Natural Gas, 1-1/4" 72734
Honeywell V8943B-1028, Natural Gas, 1-1/4" 50170
1
1
1
1
1
1
1
1
15
Honeywell V8944B-1019 Natural Gas, 1"
50177
1
1
1
1
1
1
Honeywell V8944B-1027 Natural Gas, 1-1/4" 50178
Honeywell V8944B-1035 Natural Gas, 1-1/2" 50179
Honeywell V88A-1626, LP Gas, 1-1/4" 72734
Honeywell V8943C-1026, LP Gas, 1-1/4" 50175
Honeywell V88A-1634, Natural or LP Gas, 1-1/2" 72735
Honeywell V8943B-1036, Natural Gas, 1-1/2" 50171
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Page 49
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Number of Sections with Item Quantities Below
Ref # Name of Part
Part #
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21
—
Manual Main Shut Off Valve, 1"
62023
1
1
1
1
1
1
Manual Main Shut Off Valve, 1-1/4"
Manual Main Shut Off Valve, 1-1/2"
Manual Pilot Shut Off Valve,
62024
62025
62028
50961
72743
72739
1
1
1
1
1
1
1
1
1
1
1
2
1
2
2
—
—
—
—
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
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
Pilot Regulator RV12LT
Pilot Ass'y PSE-NA29, Natural Gas
Pilot Ass'y PSE-NA29, LP Gas
Intermittent Pilot Ignition Controls
Pilot, Intermittent, Natural Gas
—
—
—
—
50978
50998
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
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
LP Pilot Orifice for the above pilot
Intermittent Ignition Module, S8610M 51180
Pilot Gas Solenoid Valve V8046C-1014 1/4" 51099
Continuous Pilot Ignition Controls
—
—
—
—
Pilot, Continuous, Natural Gas
LP Pilot Orifice for the above pilot
Pilot Flame Sense Switch
Automatic Pilot Switch
50972
50998
51188
50970
63265
63266
63267
63268
63269
63270
63271
63272
63273
72694
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
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
27 + 28 Burner Base Less Sides
1
1
1
1
2
1
1
1
2
1
1
1
1
2
1
1
1
1
2
1
1
1
1
1
1
29
—
—
Burner Base Side Panels
Burner Base Splice Plates
Burner Base Bolts
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
60246 12 12 12 12 12 12 12 12 32 32 32 32 32 32 32 32 32
60245 16 16 16 16 16 16 16 16 40 40 40 40 40 40 40 40 40
Burner Base Nuts
37
38
39
Base to Section Insulation, (25 foot roll) 60201
1
1
1
1
1
1
1
1
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
Cast Iron Section, Right Side
Cast Iron Section, Intermediate
w/o tapping
3650
3666
40
Cast Iron Section, Intermediate
w/ 3" tapping, (steam boilers)
3649
1
1
1
1
1
2
2
2
2
2
2
3
3
3
3
3
3
Page 50
GB300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS
Number of Sections with Item Quantities Below
Ref # Name of Part
Part #
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21
41
42
Cast Iron Section, Left Side
3651
1
1
1
1
1
1
9
9
9
1
1
1
1
1
1
1
1
1
1
1
Gasket, Upper Port
Gasket, Lower Port
3/8" Rope, 42" length
Draw Rod 1/2" x 7-1/2"
1/2 Flat Washer
60248
60249
71601
4
4
4
5
5
5
6
6
6
7
7
7
8
8
8
10 11 12 13 14 15 16 17 18 19 20
10 11 12 13 14 15 16 17 18 19 20
10 11 12 13 14 15 16 17 18 19 20
—
44
45
46
48
60358 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
62098 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
60875 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
1/2 Hex Nut
Cleanout Cover
69696
69697
69698
69699
65135
65136
65137
65138
72695
72696
1
1
1
2
2
2
1
1
2
4
4
4
3
1
2
2
1
3
1
2
1
1
4
1
2
1
1
1
2
1
2
49
50
Cleanout Cover Insulation
1
1
3
1
2
2
1
3
1
1
2
2
1
1
4
1
1
2
2
1
1
1
1
2
2
1
2
1
Cleanout Cover Hardware Set
Cleanout Cover Hardware Set
2
1
1
4
4
4
2
2
2
Water Controls & Trim
52
53
Temperature Pressure Gauge
Aquastat L4006A
60265
50511
50502
50507
61997
61998
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
Well 3/4" x 3"
Aquastat, (manual reset) L4006E
3/4" x 1" Relief Valve 40#, (water)
1" x 1-1/4" Relief Valve 40#, (water)
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
54
1-1/4" x 1 1/2" Relief Valve 40#, (water) 61999
Steam Controls & Trim
54
1" x 1" Relief Valve 15#, (steam)
61982
1
1
1
1
1
1-1/4" x 1-1/2" Relief Valve 15#, (steam) 61983
1
1
1
1
1
1
1
1-1/2" x 2" Relief Valve 15#, (steam)
Steam Pressuretrol PA404A-1009
L4079B-1033 Steam Pressuretrol, (manual reset)
Steam Gauge
61984
50493
50495
60268
61931
51005
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
55
56
—
58
59
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
Gauge Glass Set
M&M 67-S-2 Low Water Cut-off
Page 51
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 manufacture’s instructions to avoid
exposure to fuel substances 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.The ceramic combustion chamber in the burner box and its gasket contain crystalline
silica. Wear a tightly fitted dust mask when servicing the burner and gently handle the burner and its
gasket to prevent inhalation of airborne fibers. Crystalline silica fibers have been identified as
carcinogenic, or possibly carcinogenic when inhaled.
WESTCAST, INC.
260 NORTH ELM STREET WESTFIELD, MA 01085
TEL. (413) 562-9631 FAX (413) 562-3799
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