Smith Cast Iron Boilers GT Series manual General Plumbing Guidelines

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GT INSTALLATION AND OPERATION INSTRUCTIONS

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The following are important rules that must be followed when constructing the condensate system:

1.Connect the condensate trap to the drain using 1/2 in, 13 mm, silicone, rubber, reinforced nylon, or PEX tubing. Long runs must be properly pitched and supported to prevent blockage.

2.Do not use nylon tubing, as it will collapse, blocking drainage. This could damage the boiler.

3.Do not seal the opening between the condensate pipe and the condensate drain pipe, Figure 19. In the event of a blocked drain the opening will allow the condensate to overflow and prevent the boiler from flooding.

4.Never have the drain pipe higher than the hole in the back cabinet, this will flood the boiler.

5.Never allow the drain to freeze or become blocked. This will cause condensate to fill the combustion chamber resulting in a no heat condition and damage to the boiler.

6.NEVER use copper, steel, or galvanized piping in the construction of the condensate system.

7.When a condensate pump is used or required, select a pump that is designed for residential furnaces.

GENERAL PLUMBING GUIDELINES

If connecting this boiler to a system containing cast iron radiation, be sure to add a strainer to the system to trap any sediment that may dislodge. Failure to do this could harm the heat exchanger and void the warranty! The use of non-oxygen barrier radiant tubing is acceptable, provided that non-ferrous pipe, valves, and fi ttings are used throughout the entire hydronic system.

CAUTION: All heating system piping must be installed in accordance with the ANSI/ASME Boiler and Pressure Vessel Code, Section IV. All applicable local codes and ordinances must also be followed. If the boiler is installed above any radiation elements it must be fitted with a low water cutoff device installed above the normal boiler water level!

CAUTION: This boiler must have adequate water flowing through it whenever the burner is on. Failure to do this will damage the unit and void the warranty!

CAUTION: All systems must be flushed to remove sediment, flux, filings and other foreign matter. Use products such as Fernox “Superfloc” for new installations and CHR “Central Heating Restorer” for retrofits. Also add an inhibitor to the system water to prevent limestone and magnetite deposits from forming and to protect the boiler from galvanic corrosion. An inhibitor such as CHP, “Central Heating Protector” from Fernox is recomended.

If connecting this boiler to a system containing cast iron radiation, be sure to add a strainer to the system to trap any sediment that may dislodge. Failure to do this could harm the heat exchanger and void the warranty!

The use of non-oxygen barrier radiant tubing is acceptable, provided that non-ferrous pipe, valves, and fittings are used throughout the entire hydronic system. Failure to comply with these instructions will seriously damage the boiler, voiding warranty!

CAUTION: The boiler fittings cannot support any weight. The plumbing system must be supported by the building structure. A wrench must be used to hold the boiler fittings when installing the heating system piping. Failure to do so can seriously damage the boiler, voiding warranty!

The GT hot water boiler comes from the factory ready to be piped to the heating system. The boiler must be used only in a Primary/Secondary pumping system to avoid cycling problems in systems that have poor fl ow or heating zones with very small capacities.

CAUTION: A 11⁄4 in, 32 mm, primary loop system must be used for GT-150 & 200 models regardless of the configuration of the secondary system design.

A11⁄2 in, 38 mm, primary loop system must be used for the GT-400. Failure to properly plumb the boiler may void the warranty!

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Contents North ELM Street WESTFIELD, MA 01085 TEL 562-9631 FAX 413 Gama Energy StarBoiler Ratings & Capacities ContentsBefore YOU Start Input vs Elevation Graph Boiler LocationGeneral Venting Guidelines Combustion AIRHorizontal Direct Vent Systems Horizontal Terminal Locations Separate Air Intake and Vent TerminalsWall Penetration Detail External Air Intake and Vent Systems Vertical Direct Vent Systems Debris Screen InstallationConcentric Through the Roof Condensate DrainGeneral Plumbing Guidelines Relief Valve Piping Pressure Relief ValveLow Water Cut Off, Lwco Multiple Boiler Primary LoopPrimary Loop Plumbing Secondary Loop PlumbingSingle Boiler with Indirect Hot Water Heater Multiple Boiler Installation Multiple Zones Using Circulators Multiple Zones Valves with Bypass Valve Gas Pipe Capacity Equivalent Pipe Length ChartGAS Supply Piping Thermostat Installation Electrical WiringMultiple Zones w/ Taco Valve Controller Models ZVC403 to ZVC Multiple 4 Wire Zone Valves GT Installation and Operation Instructions GT Installation and Operation Instructions Boiler Ladder Diagram Boiler Connection Diagram Sentry Display Sentry 2100T ControllerBoiler Modulation Indirect Water HeatersOutdoor Sensor 10K Setting Sentry 2100T controlRecommended Settings Recommend System Temperatures=140.6 F, 42C Determining Reset Temperature HICalc= 200F, 93C 70F, 21C /70F, 21C Normal Flue Gas Composition Natural Gas Propane Boiler SET UPOperating Instructions Ignition System Gas Valve Layout, GT-150Operational Flow Chart For Your Safety Read Before Operating Main Burner Flame Boiler Checking & AdjustmentGas Pressure Adjustment Input RateBoiler Maintenance Aquastat High Limit Wall Hung ConversionBefore set-point Trouble ShootingTemperature is Burner shuts offIgnition Sequence Air Switch is OpenAir Switch is Closed Indicates thatBoiler will not stay Two Flashes onFenwal Three Flashes onSentry Controller Creating a noise Residence. This is not a warranty issueHousing Warranty issueGT Installation and Operation Instructions Replacement Parts Exploded View Models GT150 and GT200 Replacement Parts ListReplacement Parts Exploded View Model GT400 GT Installation and Operation Instructions WESTCAST, INC

GT Series specifications

Smith Cast Iron Boilers GT Series has become a benchmark in the hydronic heating industry, renowned for its exceptional performance, durability, and efficiency. This series is designed to cater to diverse heating needs, making it a popular choice among both residential and commercial applications.

One of the standout features of the GT Series is its robust cast iron construction. The cast iron sections offer superior thermal mass, allowing for better heat retention and distribution. This characteristic ensures that the boiler operates efficiently, maintaining comfortable temperatures even during extreme cold weather conditions. The engineers at Smith have meticulously designed each section to provide maximum strength and longevity, resulting in a boiler that can withstand the test of time.

The GT Series also incorporates advanced combustion technology. It utilizes a high-efficiency burner that optimizes fuel consumption, resulting in lower operating costs for homeowners and businesses alike. The boiler is engineered to accommodate a variety of fuel types, including natural gas and propane, giving users flexibility in their energy choices. This adaptability not only enhances efficiency but also promotes environmental sustainability by allowing for the use of cleaner fuel sources.

Another notable technology featured in the GT Series is the electronic control system. This system simplifies boiler operation and enhances user convenience. The intuitive interface provides real-time feedback and diagnostics, making it easier for technicians to perform maintenance and troubleshoot any issues that may arise. Additionally, the boiler’s modulating operation adjusts the burner output according to the heating demand, further improving efficiency and comfort.

Moreover, the GT Series is designed with user-friendly installation in mind. Its compact footprint allows for easy integration into existing heating systems, minimizing space requirements. Additionally, the boiler is equipped with convenient access points for maintenance, ensuring that servicing is straightforward and can be performed without extensive downtime.

Lastly, the Smith Cast Iron Boilers GT Series is designed to meet stringent safety and performance standards. Featuring multiple safety controls and systems, it provides peace of mind for users. With a commitment to quality, efficiency, and performance, the GT Series stands out as a leading solution for hydronic heating, catering to the evolving needs of today’s energy-conscious consumers.
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