Page 22 | SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS |
WARNING: Never use an open flame to test for gas leaks. Always use an approved leak detection method. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!
Whenever the gas supply piping is pressure tested the boiler gas controls must be protected. If the test pressure is equal to, or less than 1/2 psig, 3.5 kPa, isolate the boiler by closing the manual shut off valve in the gas supply pipe to the boiler. If the test pressure is greater than, or equal to 1/2 psig, 3.5 kPa, disconnect the boiler and its individual
ELECTRICAL WIRING
Electrical Power Connections
CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation! Verify proper operation after servicing.
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/
The boiler must be grounded in accordance with the authority having jurisdiction, or if none, the latest revision of the National Electrical Code,
Line voltage field wiring of any controls or other devices must conform to the temperature limitation of type T wire at 95° F, 35° C above room temperature. Use copper conductors with a minimum size of #14 awg.
BOILER OPERATION
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!
CAUTION: The supply temperature of a boiler set for
a20° F, 11° C temperature rise must not be below 140 ° F, 60° C for an oil boiler, 149° F, 65° C for a gas boiler. Failure to protect the boiler from low return water temperatures will damage the boiler, voiding the warranty!
Water Boilers
Fill the boiler and all of the radiation with water to the required system pressure. Completely purge the system of air and adjust the system pressure as needed.
CAUTION: Thermal shock of water boilers must be avoided! Water circulation must be established before the burner is fired. If hot standby is required, special piping and operation procedures are necessary, consult your Smith representative. Failure to protect the boiler from thermal shock can damage the boiler, voiding the warranty!
Steam Boilers
Fill the boiler with water to the normal water level line of 50 1/2 in., 1.28 m from the floor.
If the boiler is connected to a hot steam line, keep the cold boiler valved off line and fire the burner until the boiler pressure exceeds the system pressure by 1 to 2 psig, 7 to 14 kPa. Slowly open the main isolation valve on the boiler to bring it on line.
CAUTION: Never place a cold boiler into service on a hot steam line or severe damage to the boiler and piping can occur voiding the warranty!
Steam entering a cold boiler will cool quickly and can cause severe steam hammer and boiler flooding. Idle boilers not valved off from the system should have an overflow installed to prevent it from being flooded.
If an overflow trap is not installed per Figure 24, and the boiler becomes flooded, the flooded boiler must be heated to a near steaming condition, 210° F, 99° C, then drained to the correct water level.
Water and Steam Boilers
Follow the burner manufactures lighting instructions that were supplied with the burner.
WARNING: Never attempt to start the burner if the combustion chamber contains excess oil or gas, when the boiler is full of vapor or the combustion chamber is very hot. Failure to comply with this warning can result in an explosion causing extensive property damage, severe personal injury or death!
A properly adjusted gas burner on high fire will produce a CO2 of 8.5 to 9.5% with a CO level under 300 ppm. When firing on oil at high fire, the burner should be adjusted to produce a CO2 of 11.0 to 12.0% with a zero smoke. The flue gas samples should be taken at the smoke hood. Confirm proper burner adjustment with a calibrated combustion analyzer.