Smith Cast Iron Boilers 28He Users Manual

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SERIES 28HE

GAS OR OIL BOILER

INSTALLATION & OPERATING

INSTRUCTIONS

DESIGNED AND TESTED ACCORDING TO A.S.M.E. BOILER AND PRESSURE

VESSEL CODE, SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE

OF: 15 PSI STEAM OR 80 PSI WATER.

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 IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch. Do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas

supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or

the gas supplier.

WESTCAST, INC.

260 NORTH ELM STREET WESTFIELD, MA 01085

TEL. (413) 562-9631 FAX (413) 562-3799

INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER.

CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.

FOR JACKET ASSEMBLY AND BURNER SET UP SEE SEPARATE INSTRUCTIONS.

TO INSTALLER

NOTE: READ THESE INSTRUCTIONS CAREFULLY. THEY WILL

SAVE YOU VALUABLE TIME WHEN ASSEMBLING THE BOILER.

28HE-IOM-1

In Canada: 5211 Creekbank Road, Mississauga, Ont. L4W 1R3 (905) 625-2991 Fax (905) 625-6610

Page 2 SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

CONTENTS

Before You Start .................................................page 2

Boiler Ratings & Capacities................................page 2

Boiler Location ...................................................page 2

Combustion Air & Ventilation ..............................page 3

Chimney & Vent Pipe Connections ....................page 4

Common Vent Systems ......................................page 6

Boiler Assembly ................................................ page 7

General Piping Requirements ..........................page 14

Water Boiler Piping ..........................................page 15

Steam Boiler Piping..........................................page 18

Burner Installation ............................................page 21

Electrical Wiring ...............................................page 22

Boiler Operation .............................................. page 22

Boiler Checking & Adjustment..........................page 23

Boiler Maintenance ..........................................page 24

Repair Parts .....................................................page 25

Health Warnings .......................................... back cover

BEFORE YOU START

This manual covers the assembly, installation, operation

and maintenance of a Series 28HE low pressure steam

or hot water boiler.

The 28HE Series boilers are supplied completely

knocked down for field assembly, knocked down but with

an assembled block or as complete factory assembled

packaged boilers. All boiler components should be

inspected for damage upon receipt. Any damage should

be immediately reported to the trucker or wholesaler. All

boiler components should be stored in a clean dry area.

To obtain the safe, dependable, efficient operation and

long life for which this boiler was designed, these

instructions must be read, understood and followed.

The Series 28HE boilers have been design certified by

CSA. Each unit has been constructed and hydro-

statically tested for a maximum working pressure of 15

psi for steam, 80 psi for water, in accordance with

Section IV of the A.S.M.E. Boiler and Pressure Vessel

Code for cast iron boilers.

All aspects of the boiler installation must conform to the

requirements of the authority having jurisdiction, or, in

the absence of such requirements, to the National Fuel

Gas Code, ANSI Z223.1/NFPA 54-latest revision or to

the Installation of Oil Burning Equipment, ANSI/NFPA

31.

Where required by the authority having jurisdiction, the

installation must conform to the Standard for Controls

and Safety Devices for Automatically Fired Boilers,

ANSI/ASME CSD-1.

In Canada, the installation must be in accordance with

the requirements of CAN/CGA B149.1 or .2, Installation

Code for Gas Burning Appliances and Equipment.

In the Commonwealth of Massachusetts the installation

of a gas burner must be performed by a licensed

plumber or gas fitter.

The owner should maintain a record of all service work

performed with the date and a description of the work

done. Include the name of the service organization for

future reference.

Direct all questions to your Smith Cast Iron Boiler

distributor or contact the Smith Customer Service

Department. Always include the model and serial

numbers from the rating plate of the boiler in question.

BOILER RATINGS & CAPACITIES

Before undertaking the installation of the 28HE Series

boiler check the boiler rating plate to ensure that the

boiler has been sized properly for the job. The “Net

I=B=R Ratings” specify the equivalent amount of direct

cast iron radiation that the boiler can supply under

normal conditions. Also ensure that the boiler has been

set up for the type of fuel available at the installation

site.

BOILER LOCATION

1. Locate the boiler in an area that provides good

access to the unit. A minimum distance of 6 in,

0.15m

must be maintained between the boiler

and combustible construction. Servicing may

require the removal of jacket panels so service

clearances should be maintained. Allow a minimum

clearance of 3 ft,

0.9 m

between adjacent

construction and the left side, front and smoke hood.

A minimum clearance of 2 ft,

0.6 m

should be

maintained between adjacent construction and the

right side and back of the boiler. Accessibility

clearances should take precedence over minimum

clearances to combustible construction, Figure 1.

2. An optimum site will be level, central to the piping

system, close to a chimney and have adequate

fresh air for combustion.

3. The boiler should be installed on a level, flat,

concrete floor or pad that is structurally sound and

will support the weight of the boiler. If a concrete

pad is used it must be at least 2" thick. Never install

the boiler on a concrete floor or pad that contains

wires, cables, water pipes or hoses. This boiler is

designed for non combustible floors!

Page 3

SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

Figure 1 -Service Clearances to Adjacent Construction

WARNING: Never install a 28HE boiler on top of

combustible flooring without consulting the

local building authorities for proper installation

guidelines! A minimum clearance of 6 in,

0.15 m

must be maintained between the boiler

and combustible construction. Failure to comply

with this warning may result in a fire causing

extensive property damage, severe personal

injury or death!

4. DO NOT install this boiler in a location that would

subject any of the electrical components to direct

contact with water or excessive moisture during

operation or servicing.

5. DO NOT place this boiler in a location that would

restrict the introduction of combustion air into the

boiler.

WARNING: Never store combustible materials,

gasoline or any product containing flammable

vapors or liquids in the vicinity of the boiler.

Failure to comply with this warning can result

in an explosion or fire causing extensive

property damage, severe personal injury or

death!

COMBUSTION AIR & VENTILATION

WARNING: This boiler must be supplied with

combustion and ventilation air in accordance

with Section 5.3, Air for Combustion &

Ventilation, of the latest revision of the National

Fuel Gas Code, ANSI Z223.1/NFPA 54 and all

applicable local building codes. Canadian

installations must comply with CAN/CGA B149.1

or .2 Installation Code. Failure to provide

adequate combustion air for this boiler can

result in excessive levels of carbon monoxide

which can result in severe personal injury or

death!

To operate properly and safely this boiler requires a

continuous supply of air for combustion. An adequate

supply of air must be available to replace the air used

by the combustion process. NEVER store objects on or

around the boiler.

CAUTION: Never use an exhaust fan in the boiler

room. The boiler room must never be under a

negative pressure or improper burner operation will

occur!

NOTE: Forced make-up air supplied to the boiler

room must be approved by the local authorities.

A minimum of 30 ft3/GAL,

0.22 m

3

/L

for oil or

20 ft3/100 MBH (Therm),

0.024 m

3

/kW

for gas must

be provided.

Page 4 SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

All Air From Inside The Buidling

If the boiler is to be located in a confined space mini-

mum clearances of 24 in,

610 mm

must be maintained

between the boiler and any adjacent construction. When

installed in a confined space, two permanent openings

communicating with an additional room(s) are required.

The combined volume of these spaces must have

sufficient volume to meet the criteria for an unconfined

space. The total air requirements of all fuel burning

equipment or any type of exhaust fan must be

considered when making this determination.

Each opening must have a minimum free area of 1 in2/

1000 Btu/hr, 140 in2/GPH,

2200 mm

2

/kW

based on the

total input rating of ALL fuel burning equipment in the

confined area. Each opening must be no less than 100

in2,

64,516 mm

2

in size. The upper opening must be

within 12 in,

305 mm

of, but not less than 3 in,

76 mm

from, the top of the enclosure.

The bottom opening must be within 12 in,

305 mm

of,

but not less than 3 in,

76 mm

from, the bottom of the

enclosure.

All Air From Outside The Building

When installed in a confined space Two permanent

openings communicating directly with, or by ducts to,

the outdoors or spaces that freely communicate with the

outdoors must be present. The upper opening must be

within 12 in,

305 mm

of, but not less than 3 in,

76 mm

from, the top of the enclosure. The bottom opening must

be within 12 in,

305 mm

of, but not less than 3 in,

76 mm

from, the bottom of the enclosure.

Where directly communicating with the outdoors or

communicating with the outdoors through vertical ducts,

each opening shall have a minimum free area of 1 in2/

4000 Btu/hr, 35 in2/GPH,

550 mm

2

/kW

of the total input

rating of all of the equipment in the enclosure.

Where communicating with the outdoors through

horizontal ducts, each opening shall have a minimum

free area of 1 in2/2000 Btu/hr, 70 in2/GPH,

1100 mm

2

/

kW

of the total input rating of all of the equipment in

the enclosure. When ducts are used, they must have the

same cross-sectional area as the free area of the

opening to which they connect. When calculating the

free area necessary to meet the make-up air

requirements of the enclosure, consideration must be

given to the blockage effects of louvers, grills and

screens. Screens must have a minimum mesh size of

1/4 in,

6.4mm

. If the free area through a louver or grill

is not known the louver or grille should be sized per

Table 1.

Table 1 - Make-up Air Louver Sizing

Required Cross Sectional Area (in2)

Metal Wooden

Input 1/4" Wire Louvers Louvers

(MBH) Screen 75% Free Area 25% Free Area

1000 250 333 1000

1200 300 400 1200

1400 350 467 1400

1600 400 533 1600

1800 450 600 1800

2000 500 667 2000

2200 550 733 2200

2400 600 800 2400

2600 650 867 2600

2800 700 934 2800

3000 750 1000 3000

3200 800 1066 3200

3400 850 1134 3400

3600 900 1200 3600

3800 950 1267 3800

4000 1000 1334 4000

4200 1050 1400 4200

4400 1100 1467 4400

4600 1150 1533 4600

4800 1200 1600 4800

CHIMNEY & VENT PIPE

CONNECTIONS

WARNING: The vent installation must be in

accordance with Part 7, Venting of Equipment,

of the National Fuel Gas Code, ANSI Z223.1/

NFPA 54-latest revision, the ASHRAE Equipment

Handbook on Venting or applicable provisions

of the local building codes. Canadian

installations must comply with CAN/CGA B149.1

or .2 Installation Code. Improper venting of this

boiler can result in excessive levels of carbon

monoxide which can result in severe personal

injury or death!

CAUTION: The products of combustion from a 28 HE

must be safely vented to the outdoors while

ensuring that the flue gasses do not cool

prematurely. It’s critical that the chimney system be

properly designed to handle the relatively cool flue

gas temperatures. An oversized or uninsulated

chimney will cause the moisture in the flue gases

to condense resulting in damage to the chimney

system unless it’s specifically designed for

condensate. If this is the case a suitable condensate

drain must be used to protect the boiler from

condensate.

NOTE: Our warranty does not cover corrosion

damage to the boiler or its vent system caused by

flue gas condensate!

Page 5

SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

Chimney Inspection & Sizing

If this boiler will be connected to a masonry chimney, a

thorough inspection of the chimney must be performed.

Ensure that the chimney is clean, properly constructed,

lined and properly sized, see Figure 2. Table 2 lists the

equivalent breeching and flue sizes required for the

28HE boilers.

Table 2 - Equivalent Breeching & Chimney Size

Boiler Model Breeching Size Chimney Size

in

mm

in

mm

28HE-4 10

254

10

254

28HE-5 10

254

10

254

28HE-6 10

254

10

254

28HE-7 12

305

12

305

28HE-8 12

305

12

305

28HE-9 14

356

14

356

28HE-10 14

356

14

356

28HE-11 14

356

14

356

28HE-12 14

356

14

356

28HE-13 14

356

14

356

28HE-14 16

406

16

406

28HE-15 16

406

16

406

28HE-16 16

406

16

406

28HE-17 18

406

18

406

28HE-18 18

457

18

457

Note: These sizes are based on a 20 foot chimney height.

Figure 2- Vertical Venting

The 28HE is designed for pressurized operation with a

back pressure of 0.10 in,

2.54 mm

W.C. before the

smoke hood slide damper. If the vent configuration

results in a back pressure greater than this, the burner

capacity may have to be verified. Contact the Smith

Technical Service Department to verify the burner

capacity.

The chimney must be able to provide 0.10" WC at the

boiler outlet. If the chimney is 50 ft. or taller it may

produce excessive draft (appox. - 0.25" WC) and a

barometric draft regulator may be needed.

When more than one appliance is connected to the

same chimney flue the flue must be large enough to

safely vent the combined output of all the appliances.

WARNING: If an appliance using any type of

a mechanical draft system operating under

positive pressure is connected to a chimney

flue, never connect a Category I appliance to

this flue. Doing so can result in the

accumulation of carbon monoxide which can

cause severe personal injury or death!

Page 6 SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

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!

COMMON VENT SYSTEMS

If an existing boiler is removed from a common venting

system, the common venting system may then be too

large for the proper venting of the remaining appliances

connected to it. At the time of removal of an existing

boiler, the following steps shall be followed with each

appliance remaining connected to the common venting

system placed in operation, while the other appliances

remaining connected to the common venting system are

not in operation.

Au moment du retrait d'une chaudière existante, les

mesures suivantes doivent être prises pour chaque

appareil toujours raccordé au système d'évacuation

commun et qui fonctionne alors que d'autres appareils

toujours raccordés au système d'évacuation ne

fonctionnent pas: système d'évacuation

a) Seal any unused openings in the common venting

system.

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.

Inspecter de façon visuelle le système d'évacuation

pour déterminer la grosser et l'inclinaison

horizontale qui conviennent et s'assurer que le

système est exempt d'obstruction, d'étranglement

de fruite, de corrosion et autres défaillances qui

pourraient présenter des risques.

VENT CONNECTIONS

WARNING: Never modify or alter any part of the

boiler’s smoke hood. This includes the removal

or alteration of any baffles. Never install a vent

pipe of a diameter different than that of the

boiler smoke hood outlet. Failure to comply with

this warning can result in severe personal injury

or death.

Locate the boiler as close to the chimney as possible.

Use the shortest, straightest vent connector possible for

the installation. If horizontal runs exceed 5 ft,

1.5 m

they

must be supported at 3 ft,

0.9 m

intervals with overhead

hangers. Use a single wall stainless or single wall

galvanized steel vent pipe the same diameter as the flue

collar to connect the boiler to a masonry chimney. When

using an approved metal chimney system use the

appropriate vent connector. The vent connector should

be sloped up toward the chimney at a minimum rate of

1/4 in/ft,

2 cm/m

. On masonry chimneys the connector

must terminate flush with the inside of the chimney flue.

Fasten each single wall vent connection with at least 3

corrosion resistant sheet metal screws.

The vent materials used in positive pressure vent

systems must be certified to UL 1738 for installations

in the United States, ULS636 for installations in Canada.

The following manufactures have systems that meet

these requirements:

Heat-Fab, Inc.

38 Hayward Street

Greenfield, MA 01301, (800) 772-0739.

Z-Flex U.S., Inc.

20 Commerce Park

North, Bedford, NH 03110-6911, (800) 654-5600.

Protech Systems Inc.

26 Gansevoort Street

Albany, NY 12202 (518) 463-7284

WARNING: Breeching under positive pressure

must be certified to UL 1738 for installations in

the United States, ULS636 for installations in

Canada. Type B1 vent SHALL NOT be used.

Failure to comply with this warning can result

in severe personal injury or death.

Always provide a minimum clearance of 6 inches

between single wall metal vent pipe and all combustible

materials.

Page 7

SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

c) Insofar as is practical, close all building doors and

windows and all doors between the space in which

the appliances remaining connected to the common

venting system are located and other spaces of the

building. Turn on clothes dryers and any appliance

not connected to the common venting system. Turn

on any exhaust fans, such as range hoods and

bathroom exhaust, so they will operate at maximum

speed. Do not operate a summer exhaust fan for a

boiler installation. Close fireplace dampers.

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.

d) Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust thermostat so

appliance will operate continuously.

Mettre l'appareil inspecté en marche. Suivre les

instructions d'allumage. Régler le thermostat de

façon que l'appareil fonctionne de façon continue.

e) Test for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use the flame

of a match or candle, or smoke from a cigarette,

cigar or pipe.

Faire fonctionner le brûleur principal pendant 5 min

ensuite, déterminer si le coupetirage déborde à

l'ouverture de décharge. Utiliser la flamme d'une

allunette ou d'une chandelle ou la fumée d'une

cigarette, d'un cigare ou d'une pipe.

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.

Une fois qu'il a été d éterminé, selon la métode

indiquée cidessus, que chaque appareil raccordé au

système d'évacuation est mis à l'air libre de façor

adéquate. Remettre les portes et les fenêtres, les

ventilateurs, les registres de cheminées et les

appareils au gaz à leur position originale.

g) Any improper operation of the 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

Appendix F in the National Fuel Gas Code, ANSI

Z223.1/NFPA 54 and or CSA B149 Installation

Codes.

Tout mauvais fonctionnement du systéme

d'évacution commun devrait étré corrigé de façor

que l'installation soit conforme au National Fue Gas

Code, ANSI Z223.1/NFPA 54 et (ou) aux codes

d'installation CAN/CGA-B149. Si la grosseur d'une

section du système d' évacuation doit étré modifiée,

le système devrait étré modifié pour respecter les

valeurs minimales des tableaux pertinents de

l'appendice F du National Fuel Gas Code, ANSI

Z223.1/NFPA 54 et (ou) des codes d'installation

CSA-B149.

BOILER ASSEMBLY

Locate the boiler installation site based on the guide-

lines set forth in the BOILER LOCATION section.

WARNING: Never install a 28HE boiler on top of

comustible flooring without consulting the local

building authorities for proper installation

guidelines! Failure to comply with this warning

can result in a fire causing extensive property

damage, severe personal injury or death!

Packaged Boilers/Factory Assembled Sections

A careful inspection of all assemblies should be made

to detect possible shipping damage. Packaged boilers

and factory assembled blocks of sections are

hydrostatically tested at the factory to insure pressure

tightness. A hydrostatic retest should be performed

before any piping connections are made to detect leaks

caused by shipping.

NOTE: All assembled boiler sections shall pass the

hydrostatic tests prescribed in Section IV of the

ASME Boiler and Pressure Vessel Code.

CAUTION: Do not connect any boiler controls during

the pressure test or they will be damaged!

Page 8 SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

2. Carefully place the back section in position on the

angles as shown in Figure 4.

WARNING: The section MUST be fully supported

to prevent it from falling! Failure to comply with

this warning may result property damage,

severe personal injury or death!

Figure 4 - Section Placement

3. Clean the hydronic port connector sealing surfaces

and the rope grooves with a wire brush to remove

any rust or debris.

4. Apply two coats of the spray adhesive supplied with

the boiler to the rope groove. Allow time for the first

coat to dry before applying the second coat. When

the second coat is tacky press the rope into the rope

groove. Trim the rope off leaving 1/8 in.,

3.2 mm

extending beyond the surface of the cast iron

section, Figure 5.

Figure 5 - Rope Installation

Completed boilers must be tested as follows:

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.

WARNING: Never leak test the boiler using

compressed air! Failure to comply with this

warning may result in property damage, severe

personal injury or death!

1. Plug all openings in the boiler and fill it with water.

2. Bleed any air off through one of the top tappings

then increase the pressure as outlined above.

3. Maintain the test pressure while carefully checking

for leaks. If a leak is found it must be eliminated,

see Table 4 and supporting text. Once the

assembled boiler sections pass the hydrostatic test

drain them and remove the plugs from any tappings

that will be used in service.

NOTE: The shipping lugs, lifting lugs and metal

banding should be removed before installing the

jacket on factory assembled sections.

CAUTION: Remove the left jacket panels on fully

packaged boilers and ensure that the cleanout

covers are secure and gas tight. Loose covers could

damage the boiler.

Assembly of Knocked-Down Boilers

Drilled and tapped steel angles are furnished to provide

a level footing, ease of section assembly and a point of

jacket attachment.

1. Set the angles as shown in Figure 3. They must be

parallel and level. Grout under the angles to provide

a continuous bearing surface.

Figure 3 - Steel Angle Placement

Page 9

SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

5. Insert the large port connector with its steel inner

ring into the upper port.

6. Insert the two round port connectors into the lower

ports.

NOTE: Apply the spray adhesive supplied with the

boiler to the port recess to hold the port connector

in place if necessary.

7. Select the correct intermediate section and carefully

move it into place against the back section, Figure

4.

CAUTION: Any steam uptake and heater sections

must be located as shown in Table 3. Failure to

comply with this caution may result in poor boiler

performance and prevent the jacket from fitting!

Only one intermediate section with an external leg

boss has been included. It should be located toward

the front of the boiler for optional low water cutoff

use. See Table 3.

NOTE: A putty knife or similar tool can be used to

hold the port connectors in place while the

intermediate section is positioned. It must be

removed before the sections make contact or the

port connector will be damaged resulting in a leak!

8. Insert the four draw rods through the casting

bosses. Thread nuts onto one end of the rods.

Place washers on the other end of the rods before

threading nuts onto them. Snug the nuts finger tight.

Use a spirit level to ensure that the first two sections

are plumb and properly aligned, Figure 6. Check the

rope to insure that it’s properly positioned. Once the

sections are plumb and the rope and port

connectors are properly positioned follow the torque

sequence shown in Table 4.

Figure 6 - Section Alignment

Table 4 - Section Torque Sequence

Step Rod Position Torque

ft lbs

Nm

1 Upper Right 25

34

2 Lower Left 25

34

3 Lower Right 25 34

4 Upper Left 10

14

5 Upper Right 50

68

6 Lower Left 50

68

7 Lower Right 50

68

8 Upper Right 75

102

9 Lower Left 75

102

10 Lower Right 75

102

11 Upper Left 30

42

12 Upper Right 125

169

13 Lower Left 125

169

14 Lower Right 125

169

15 Upper Right 125

169

16 Upper Left 40

54

NOTE: With these initial torques the sections may

not be metal to metal, which is acceptable. If any of

the ports leak during the hydrostatic test the torque

can be increased to 200 ft lbs,

271 Nm

on the upper

right rod. The torque on the lower left and right rods

can be increased to 150 ft lbs,

203 Nm

. Once the

sections are metal to metal additional torque will not

improve the seal.

Boiler Section Location Numbered From Front To Back

Model 123456789101112131415161718

28HE-4 F T H B F Front Section

28HE-5 F H T H B T Intermediate Section w/ 5" Tapping & Boss

28HE-6 F T H T H B H Intermediate Section w/ Heater Opening

28HE-7 F T H P T H B P Intermediate Section, Plain

28HE-8 F T H P H T H B B Back Section

28HE-9 F T H P H P T H B

28HE-10 F H T H P H P T H B

28HE-11 F H T H P T P T H B

28HE-12 F H T H P T H P H T H B

28HE-13 F H T H P H T P P H T H B

28HE-14 F H T H P H T H P H P T H B

28HE-15 F H T H P H P T H P H P T H B

28HE-16 F H T H P H P H T H P H P T H B

28HE-17 F H T H P H P H T H P H P H T H B

28HE-18 F H T H P H P H P T H P H P H T H B

Table 3 - Section Locations

Page 10 SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

9. Assemble the rest of the sections following steps 3

through 8 above.

10. Hydrostatically test the boiler by following the

instructions on page 8.

11. While the boiler is being filled confirm that all

of the draw rods are properly torqued and that

there are no leaks.

12. If any leaks are found tighten the draw rods on that

section until the leak stops.

Heat Transfer Rod Installation, Figure 7

The high efficiency 28HE comes with design certified

heat transfer rod sets. Each tube of 15 heat transfer rods

will baffle one flue. In order to obtain the high efficiency

for which the boiler was designed, the heat transfer rods

must be properly installed, Figure 7.

Figure 7 -Heat Transfer Rod Installation

Cleanout Cover Installation

1. The cleanout covers come insulated from the

factory. Inspect the covers to ensure that the

insulation is not damaged or missing. If it is call the

Smith Customer Service Department.

2. Trim the 1/2" rope that’s sticking out around the

cleanout opening flush with the castings to insure

an air-tight seal, see Figure 5.

3. Install the cleanout cover bolts from the baffled side

of the cleanout cover and start the nuts, Figure 8.

4. Rotate the bolts so the cam heads fit between the

cleanout cover bosses on the castings.

5. Insert the cleanout cover and tighten the nuts to

15 ft lbs,

21 Nm

.

6. Apply a bead of high temperature silicone caulk

around the perimeter of the cleanout cover to

ensure an air tight seal.

Figure 8 - Cleanout Cover Assembly

Burner Mounting Plate Installation, Figure 9

1. Apply two coats of the spray adhesive supplied with

the boiler to the rope groove on the plate. Allow time

for the first coat to dry then apply the second coat.

When the second coat is tacky lay the 3/8" rope into

the rope groove and press in place.

2. Screw the four 7/16-14 x 2 1/2" studs into the

tapped holes in the boiler front section, Figure 9.

3. Install the burner mounting plate insulation block in

the burner opening in the front section of the boiler.

The small observation port cutout must be on the

top, left side.

4. Position the front jacket panel frame over the four

studs, Figure 9.

5. Align the four holes in the burner mounting plate

with the 7/16" studs and force the burner insulation

block inward until the studs extend far enough

through the burner mounting plate holes so the nuts

can be started. Lightly tighten the nuts.

6. Carefully insert the 1/4-20 x 5" machine screws

through the holes in the burner mounting plate and

insulation block, Figure 9. Reach through the inside

of the burner opening and install the stainless steel

fender washers and nuts and snug the nuts down.

CAUTION: The burner insulation block must be

supported from the inside to prevent it from tearing.

Don't force the bolts through the block or over

tighten the nuts or the block with be damaged!

Page 11

SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

Observation Port Assembly, Figure 10

1. Position the hinged end of the steel flapper door,

item 5, over the boss on the observation port cover,

item 4.

2. Drive the expansion pin, item 7, through the hinge

bosses to secure the door to the cover.

3. Insert the hex bolt, item 6, through the hole in the

observation port cover.

4. Install the spring, nut and knob, items 3, 2 & 1 on

the bolt as shown. Use the nut, item 2, as a jam

nut against the knob, item 1.

5. Apply the insulating tape to the back of the

observation port cover as shown.

Figure 9 - Burner Mounting Plate Details

Figure 10 - Observation Port Assembly

Page 12 SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

Observation Port Installation

1. Screw the four 5/16-18 x 1 1/2" studs into the

tapped holes around the observation cover opening

in the back section.

2. Place the observation port cover assembly over the

studs and install the washers and nuts. Tighten the

nuts uniformly.

Smokehood Installation, Figure 11

1. Screw the four 5/16-18 x 1 1/2" studs into the

tapped holes around the smokehood opening in the

back section.

2. Apply smokehood insulation tape to smokehood.

3. Place the smokehood over the studs and install the

washers and nuts. Tighten the nuts uniformly.

4. Apply the 1/8" x 3/4" x 18" strip of insulating tape

to the damper anchoring angle, Figure 11.

5. Fully open the slide damper and leave it ready for

adjustment during burner light off.

Figure 11 - Smokehood Assembly

Page 13

SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

Tankless Heater Installation - Optional

1. Clean the heater flange to remove any rust or

debris.

2. Install the four 7/16" x 1 1/2" studs into the tapped

holes in the tankless heater flange on the section,

Figure 12.

Figure 12 - Tankless Heater Installation

3. Place the heater gasket over the studs and carefully

install the heater.

4. Install the nuts and tighten evenly to ensure uniform

compression of the gasket.

5. Install the operating control in one of the heater

mounting plates to ensure quick burner response

when there is a demand for hot water. Figure 13

illustrates an acceptable piping arrangement for

multiple heaters.

Burner Mounting

1. Clean the burner mounting flange to remove any

rust or debris.

2. Install the four 3/8" x 1 1/4" studs into the tapped

holes in the burner mounting plate.

3. Use a hacksaw blade, or some other suitable tool,

to properly size the opening in the burner mounting

plate insulation block to match the burner air tube

end diameter.

NOTE: The opening should be a close fit, but not too

snug or the insulation block may be damaged upon

burner insertion!

4. Place the burner gasket, supplied with the burner,

over the studs and carefully insert the burner into

the opening in the burner mounting plate.

CAUTION: Most burners require support to the floor.

Follow the burner manufacturer's instructions or the

burner may be damaged!

5. Install the 3/8" washers and nuts and tighten

securely.

Figure 13 - Multiple Tankless Heater Piping

Page 14 SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

Figure 15 - Back Section Tapping Locations

Table 5 - Water & Steam Tappings

Relief & Safety Valve Piping

Install the pressure relief or safety valve in the 3" NPT

opening in the top of the back section, Figure 14.

WARNING: The discharge of the pressure relief

or safety valve must be piped close to the floor

to prevent scalding in the event of a discharge,

see Figure 16. The discharge piping must be

sized the same as the pressure relief or safety

valve outlet. Never install any type of valve

between the boiler and the pressure relief or

safety valve! Failure to comply with this

warning can result in an explosion causing

extensive property damage, severe personal

injury or death!

GENERAL PIPING REQUIREMENTS

CAUTION: Never use automotive antifreeze in the

boiler or heating system. If antifreeze is necessary

it must be formulated specifically for hydronic

heating systems, such as ethylene or propylene

glycol. Failure to comply with this caution will void

the warranty!

All heating system piping must be installed by a qualified

technician in accordance with the latest revision of the

ANSI/ASME Boiler and Pressure Vessel Code, Section

IV. Also ANSI/ASME CSD-1, Standard for Controls and

Safety Devices for Automatically Fired Boilers where

required. All applicable local codes and ordinances must

also be followed. A minimum clearance of 1" must be

maintained between heating system pipes and all

combustible construction.

CAUTION: Improper piping of this boiler can result

in poor performance and premature failure of the

boiler voiding the warranty! Improper piping can

also cause flooding and extensive property damage!

Ensure that the boiler is level from front to back and from

side to side. Use metal shims to level the boiler. NEVER

use wood, plastic or other combustible materials as

shims.

If a boiler is installed above any radiation elements it

must be fitted with a low water cutoff device.

NOTE: Install the observation port assembly before

making any return piping connections as access

may be blocked by piping.

Figure 14 - Front Section Tapping Locations

Tapping Size Water Steam

1 1/8" Chamber Pressure Chamber Pressure

2 3/4" Probe LWCO

3 3/4" Temp./Pressure Gage

4 3/4" Operating Control - Top Water Glass

53/4" Manuel Reset Manuel Reset High

High Limit Limit & Steam Gage

6 1" Air Removal Water Column - Top

7 6" Water Supply Skim Tapping

8 3/4" Tankless Heater

Operating Control

9 1 1/2" Inspection Tapping - Top

10 1" Water Column - Bottom Water Column - Bottom

11 4" Boiler Drain Boiler Drain/Blowoff

12 4" Return Return

13 Relief Valve Safety Valve

Page 15

SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

Figure 16 - Relief & Safely Valve Piping

WATER BOILER PIPING

The supply and return connections should be sized

to suit the system, see Figures 14, 15, 17, 18 and Tables

5 & 6. Do not pipe the supply from the bottom port or

the return to the top port, the boiler will not work

properly. Typical water boiler piping arrangements are

shown in Figures 19 & 20. Swing joints should be used.

Install 3" nipples into the two 3" NPT tappings in the

front section and cap them.

NOTE: See CLEANING OF WATER BOILERS on page

18 before proceeding!

Supply Piping

Install a reducing bushing in the 6" NPT tapping in the

front section to obtain the correct supply pipe size,

Figure 14 and Tables 5 & 6.

Table 6 - Water Boiler Piping

Boiler Size Return Size Supply Size

# Sections NPT NPT

4 & 5 3 3

6 through 9 4 4

10 through 18 5 5

Note: Sizes based on 20°F, 11.1°C, ∆T for the system.

Return Piping 4 through 9 Section Boilers

Install 3" x 4" NPT bushings in the two 4" NPT tappings

at the bottom of the back section. Install two 3" NPT

x 6" nipples per Figure 17. Assemble the rest of the

return yoke as shown in Figure 17.

Table 7- Boiler Water Content

Boiler Model Water Boilers Steam Boilers

Gallons

Liters

Gallons

Liters

28HE-4 123

466

104

394

28HE-5 150

568

126

477

28HE-6 177

670

148

560

28HE-7 204

772

170

644

28HE-8 231

875

192

727

28HE-9 258

977

214

810

28HE-10 285

1079

236

893

28HE-11 312

1181

258

977

28HE-12 339

1283

280

1060

28HE-13 366

1386

302

1143

28HE-14 392

1484

324

1227

28HE-15 419

1586

346

1310

28HE-16 446

1689

368

1393

28HE-17 473

1791

399

1511

28HE-18 500

1893

412

1560

Return Piping 10 Through 18 Section Boilers

Install two 4" NPT x 6" nipples per Figure 17. Assemble

the rest of the return yoke as shown in Figure 17.

Control Installation

Locate the temperature & pressure gage, low water

cutoff, high limit and operating controls per Figures 14

& 18. Optional controls must be installed in accordance

with the control manufacturers instructions and Figures

14 & 18.

Note: The front jacket panel MUST be installed

before any controls are attached to the front boiler

section!

CAUTION: The controls must be mounted in the

correct location and according to the control

manufacturer’s instructions or the boiler may not

function properly!

Water Column Piping

A variety of water level controls are available for the

28HE. The water column piping needed to properly

mount each control is available from Smith. Figure 18

shows a typical water column piping arrangement. The

1" NPT x 7 1/2" nipple is always installed in the lower

water column tapping, Figures 14 & 18 and Table 5.

Page 16 SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

Figure 17 - Optional Return Yoke

Figure 18 - Boiler Control Locations

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, see Figure 21.

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.

WATERSTEAM

Page 17

SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

Figure 19 -

Typical Single

Water Boiler Piping

Figure 20 - Typical Multiple Water Boiler Piping

Page 18 SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

Figure 21 - Chilled Medium Diagram

Cleaning of Water Boilers

Normally the cleaning of water boilers is unnecessary

unless there is unusually heavy contamination of the

boiler or system.

The burner must be installed and made operational

along with the operating, limit and other safety controls.

The burner on oil boilers must be adjusted to prevent

sooting of the boiler flues.

Final burner adjustment should be made after the boiler

has been properly cleaned.

WARNING: The pressure relief valve must be

installed and piped to the floor to prevent

scalding in the event of a discharge, see Figure

16. The discharge piping must be sized the same

as the pressure relief valve outlet. Never install

any type of valve between the boiler and the

pressure relief valve! Failure to comply with this

warning can result in an explosion causing

extensive property damage, severe personal

injury or death!

1. Install ball valves on the two 3" NPT nipples in the

bottom of the front section and pipe to a suitable

drain.

2. Fill the boiler 3/4 full with water.

3. Make a cleaning solution by mixing 1 lb,

0.45 kg

each off caustic soda and trisodium phosphate for

every 50 ga,

189 L

of water, see Table 7.

NOTE: The water content of the heating system must

be added to the boiler water content.

CAUTION: Avoid skin contact with cleaning solution

to prevent injury! If eye or skin contact occurs flush

with large quantities of water.

NOTE

FOR HEATING: VALVES “H” OPEN, VALVES “C” CLOSED.

FOR COOLING: VALVES “H” CLOSED, VALVES “C” OPEN.

EXP. TANK

VENT

ROOM

UNIT

DRAIN

CHILLER

H

C

PUMP

RELIEF

VALVE

FILL

VALVE

DRAIN

H

BOILER

C

NOTE: Some locations do not allow this solution to

be used. Check with the local authority having

jurisdiction.

4. Mix the cleaning chemicals with water to create a

concentrated solution. Pour the cleaning solution

through one of the top tappings in the front section

and plug it.

5. Immediately fill the rest of the boiler and the heating

system with water.

6. Fire the boiler and maintain a water temperature

of 160°F to 200°F,

71

°

C to 93

°

C

it may be necessary

to cycle the boiler.

7. Run all of the system pumps during the cleaning

procedure.

WARNING: Monitor the boiler pressure

constantly during the cleaning procedure. Do

not allow the boiler pressure to exceed the

pressure listed on the pressure relief valve or a

discharge of hot water and steam will occur!

8. Shut the boiler off and allow the boiler to cool to

100°F,

38

°

C

. Open the 3" ball valves and drain the

boiler and heating system.

9. Remove the 3" ball valve and install 3" pipe caps in

the ends of the 3" NPT nipples.

10. Refill the boiler and heating system with water.

STEAM BOILER PIPING

Steam Boiler Piping Connections

Table 3 contains the steam riser location schedule. Riser,

equalizer and header pipe sizes are located in Table 8. A

typical single boiler piping arrangement is shown in Figure

22. Figures 23 & 24 contain typical piping diagrams for

steam boilers in a battery.

NOTE: See CLEANING OF STEAM BOILERS before

connecting the return piping.

CAUTION: Improper placement of steam risers will

result in poor steam quality!

Table 8 - Steam Boiler Piping Sizes

Boiler Number of Header Equalizer

Model 5" NPT Risers Size, NPT Size, NPT

4 & 5 1 5" 2 1/2"

6 & 7 2 5" 2 1/2"

8 Through 10 2 6" 4"

11 Through 18 3 8" 4"

The steam piping should be pitched so the condensate

flows in the direction of steam travel. The return tappings

should be yoked to equalize the return flow, Figure 17.

Swing joints should be used.

Page 19

SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

Minimum Feed Water Condensate Receiver

Boiler I=B=R Gross Output Evaporation Rate Pumping Rate Capacity

Model MBH

kW

GPM

L/hr

GPM

L/hr

Gallons

Liters

28HE-S-4 900

264

1.9

7.3

3.9

14.8

37

140

28HE-S-5 1166

342

2.5

9.5

5.0

18.9

48

182

28HE-S-6 1433

420

3.1

11.7

6.2

23.5

59

223

28HE-S-7 1699

498

3.7

13.8

7.3

27.6

69

261

28HE-S-8 1965

576

4.2

16.0

8.4

31.8

80

303

28HE-S-9 2232 654 4.8

18.1

9.6

36.3

91

345

28HE-S-10 2498

732

5.4

20.3

10.7

40.5

102

386

28HE-S-11 2764

810

5.9

22.5

11.9

45.1

113

428

28HE-S-12 3031

888

6.5

24.7

13.0

49.2

124 469

28HE-S-13 3297

966

7.1

26.8

14.2

53.8

135

511

28HE-S-14 3563

1044

7.7

29.0

15.3

57.9

145

549

28HE-S-15 3830

1122

8.2

31.2

16.5

62.5

156

591

28HE-S-16 4096

1200

8.8

33.3

17.6

66.6

167

632

28HE-S-17 4362

1278

9.4

35.5

18.7

70.8

178

674

28HE-S-18 4629

1356

9.9

37.6

19.9

75.3

189

716

Table 9 - Steam Boiler Capacities

Note: These recommendations are considered normal for compact buildings. Where buildings are spread out,

additional receiver capacity may be necessary because of the extended time required for condensate to return to

the receiver.

Figure 22 - Typical Single Boiler Steam Piping

Page 20 SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

Figure 23 - Typical Steam Piping - Gravity Return for Multiple Boilers

Figure 24 - Typical Steam Piping - Pumped Return for Multiple Boilers

Page 21

SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

CAUTION: Avoid skin contact with cleaning solution

to prevent injury! If eye or skin contact occurs flush

with large quantities of water.

NOTE: Some locations do not allow this solution to

be used. Check with the local authority having

jurisdiction.

5. Mix the cleaning chemicals with water to create a

concentrated solution. Pour the cleaning solution

through one of the top tappings in the front section

and plug it.

6. Immediately fire the boiler and maintain a steam

pressure of 0 to 2 psig,

0 to 13.8 kPa

. It may be

necessary to cycle the boiler.

WARNING: Monitor the boiler pressure

constantly during the cleaning procedure. Do

not allow the boiler pressure to exceed 15 PSI,

103 kPa

or a discharge of hot water and steam

will occur!

7. Adjust the water feed to prevent the build up of

pressure within the boiler. Continue the skimming

process until the discharge runs clear.

8. Shut the boiler off and allow the boiler to cool to

100°F,

34

°

C

. Remove the skim piping and plug the

tapping. Open the blowdown valve and flush the

boiler until the discharge runs clear.

9. Close the blowdown valve and fill the boiler with

water to a level 1 in.,

25 mm

below the normal water

level line.

10. Check the traps and vents for proper operation.

BURNER INSTALLATION

WARNING: The burner must be installed in

accordance with the burner manufactures

instructions. Check the boiler rating plate to

make sure that the boiler is for the type of fuel

that will be used. If it isn't, do not connect the

burner to the fuel supply. Failure to comply with

this warning can result in extensive property

damage, severe personal injury or death!

Follow the burner manufacturer’s installation instructions

for the proper installation, fuel piping, wiring, burner

adjustment and servicing. Mount the burner per the

instructions on page 13.

When applicable, provisions for vent, bleed and gas

relief lines must be made in accordance with the latest

revision of ANSI Z223.1/NFPA 54.

Install 3" nipples into the two 3" NPT tappings in the

front section and install ball valves so the boiler can be

blown down.

The feed water requirements for steam boilers at full

input are shown in Table 9. The addition of water to the

boiler should be controlled by sensing the actual boiler

water level. 1" NPT water column tappings are provided

on the front section for the mounting of the required

water level controls, see Figure 18.

CAUTION: Makeup water connections must be made

to the return piping and not to the boiler or the

boiler may be damaged voiding the warranty!

Cleaning of Steam Boilers

The burner must be installed and made operational

along with the operating, limit and other safety controls.

The burner on oil boilers must be adjusted to prevent

sooting of the boiler flues. Final burner adjustment

should be made after the boiler has been properly

cleaned.

CAUTION: Failure to properly clean the boiler can

result in foaming and surging and prevent proper

operation of the boiler! Boiler damage can occur

voiding the warranty!

NOTE: Do not connect the boiler to the return piping

until the system piping has been thoroughly flushed

or recontamination of the boiler can occur.

1. Plug the 4" NPT return tappings in the back section

and any other unused tappings, see step 5 below.

WARNING: The safety valve must be installed

and piped to the floor to prevent scalding in the

event of a discharge, see Figure 16. The

discharge piping must be sized the same as the

safety valve outlet. Never install any type of

valve between the boiler and the safety valve!

Failure to comply with this warning can result

in an explosion causing extensive property

damage, severe personal injury or death!

2. Fill the boiler with water to a level 1 in.,

25.4 mm

below the normal water level line of 50 1/2 in.,

1.28 m

from the floor.

3. Pipe a skimmer off the 6" NPT tapping in the front

section using 1 1/2" NPT pipe.

4. Make a cleaning solution by mixing 1 lb,

0.45 kg

each off caustic soda and trisodium phosphate for

every 50 ga,

189 L

of water, see Table 7.

Page 22 SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

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 25, 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.

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 shut-off valve from the gas

supply.

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/

NFPA-70. Installation should also conform with CSA

C22.1 Canadian Electrical Code Part I if installed in

Canada. Install a separate circuit properly rated for the

boiler. A shut-off switch should be located at the boiler.

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.

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

a 20°F,

11

°

C

temperature rise must not be below

140°F,

60

°

C

for an oil boiler, 149°F,

65

°

C

for a gas

boiler. Failure to protect the boiler from low return

water temperatures will damage the boiler, voiding

the warranty!

Page 23

SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

CAUTION: If the flue gas temperature exiting the

smoke hood is less than 320°F,

160

°

C

at full rated

input, the number of heat transfer rods in the boiler

must be reduced. Failure to protect the boiler from

low flue gas temperatures will shorten the life of the

boiler and breeching and void the warranty!

Flue Temperature Adjustment

1. Shut the boiler off and remove the left side jacket

panels and cleanout covers, Figure 8.

2. Remove the bottom heat transfer rod from each flue.

3. Replace the cleanout covers and fire the boiler for

at least 15 minutes.

4. Check the flue temperature. If it’s greater than

320°F,

160

°

C

, reseal the cleanout covers and install

the left side jacket panels.

5. If the flue temperature is still less than 320°F,

160

°

C

,

repeat steps 1 through 4.

BOILER CHECKING & ADJUSTMENT

CAUTION: Never increase the input to the boiler

above that for which it is rated. Doing so can cause

premature failure of the boiler!

Low Water Cutoff

Ensure that the low water cutoff device(s) function(s)

properly. Test in accordance with the manufacturer’s

instructions included with the device(s).

HI Limit

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,

116

°

C

. The aquastat high

limit cannot be repaired. If it fails to function properly

replace it.

Figure 25 - Recommended Overflow Trap Piping

Page 24 SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

BOILER MAINTENANCE

WARNING: Servicing, inspection and adjustment

of the boiler must be done by a trained

technician in accordance with all applicable

local and national codes. Improper servicing or

adjustment can result in property damage,

severe personal injury or death!

The boiler should be cleaned and inspected once a year,

before each heating season.

Heat Exchanger Cleaning

A flue temperature over 550°F,

288

°

C

, indicates that the

boiler needs to be cleaned.

1. Shut off the electrical power and the fuel supply to

the boiler.

2. Remove the left side jacket panels.

3. Remove the cleanout covers, Figure 8.

4. Remove the heat transfer rods, Figure 7, and clean

them with a wire brush if they're dirty.

5. Clean each flue passage with a wire brush.

6. If heavy deposits are present, pull the burner and

vacuum out the combustion chamber.

7. Vacuum out the burner base and clean and inspect

all of the components. Replace any damaged or

badly corroded parts.

8. Install the heat transfer rods in the correct order,

Figure 7.

9. Inspect the cleanout cover insulation and rope seal.

If damaged or deteriorated replace them.

10. Install the clean out covers and reseal them with a

silicone caulk rated for 500°F,

260

°

C

.

11. Install the left jacket panels and remount the burner.

12. Restore electrical power and fuel to the boiler.

Vent System

Thoroughly inspect the vent system for any signs of

blockage, corrosion or leakage.

Immediately replace any unsound vent system piping.

Controls

1. Low water cutoff devices must be serviced per the

manufacture’s instructions.

2. The relief valve should vent water when the test

lever is lifted. It should not weep or discharge water

at normal system pressure.

WARNING: Never try to clean or repair the relief

valve! If the valve fails to operate properly,

replace it! Failure to comply with this warning

can result in an explosion causing extensive

property damage, severe personal injury or

death!

3. Use a combustion analyzer to ensure that the

burner is adjusted properly, see BOILER

OPERATION.

Page 25

SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

Figure 26 - Boiler Assembly

Page 26 SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

(1) Smokehood assembly includes the smokehood, slide damper, angle bracket and hardware.

(2) Cleanout cover assembly includes the cleanout cover, insulation, rope and mounting hardware.

1 Front Section 3621 111111111111111

2 Graphite Port Connector Set 60375 34567891011121314151617

3 Draw Rod Washers 62099 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68

4 5/8" x 11" Draw Rods 60102 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68

5 Draw Rod Hex Nuts 60877 24 32 40 48 56 64 72 80 88 96 104 112 120 128 136

6 Rope, 1/2" x 12 1/2 feet 70660 34567891011121314151617

7 Heat Transfer Rod Set 70063 34567891011121314151617

8(2) Cleanout Cover Assembly 70360 34567891011121314151617

9 Cleanout Cover Nut 60245 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34

10 Cleanout Cover Washer 62095 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34

11 Cleanout Cover Rope Seal, 3/8" x 45" 76538 111111111111111

12 Cleanout Cover Bolt 61415 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34

13 Rear Observation Port Assembly 70614 111111111111111

69371 11111

14 Slide Damper 69372 11111

69373 1 1 1 1 1

15 Flue Outlet Increaser, 16" to 18" 69904 1 1

Smoke Hood Assembly, 10" 70633 1 1 1

16(1) Smoke Hood Assembly, 12" 70611 1 1

Smoke Hood Assembly, 14" 70612 11111

Smoke Hood Assembly, 16" 70613 11111

16A Smokehood insulating tape 74301 111111111111111

3/4" Water Relief Valve, 40 lb. 61997 1

1" Water Relief Valve, 40 lb. 61998 1 1

17 1 1/4" Water Relief Valve, 40 lb. 61999 1111

1 1/2" Water Relief Valve, 40 lb. 62000 1111

2" Water Relief Valve, 40 lb. 62002 1111

1 1/4" Steam Safety Valve, 15 lb. 61983 1 1

1 1/2"Steam Safety Valve, 15 lb. 61984 1 1

18 2" Steam Safety Valve, 15 lb. 61985 11111

2 1/2"Steam Safety Valve, 15 lb. 61986 11111

3" Steam Safety Valve, 15 lb. 61987 1

19 Back Section 3630 111111111111111

20 Intermediate Section w/ 5" Tapping & Boss 3624 Section quantities based on model ordered

Intermediate Section, Plain with Boss 3622

21 Intermediate Section, Plain w/o Boss 3658 Section quantities based on model ordered

Int. Section w/ Heater Opening w/o Boss 3623

22 Hi Limit Control, L4006E 50507 One per water boiler

23 Tankless Cover Plate & Coil Gasket 60327

24 Tankless Heater, 8 GPM, 30 L/H 50653 Quantities based on model ordered

Tankless Heater, 12 GPM, 45 L/H 50655

25 Tankless Cover Plate with Gasket 70628 Quantities based on model ordered

26 Operating Control, L4007A 50510 One per water boiler

27 3 1/2" Temperature/Pressure Gage 60267 One per water boiler

28 Gauge Glass, 5/8" x 11 1/2" 61931 One per steam boiler

29 Observation Glass Gasket, Inner 60317 1 1 1 1 1 1 1 1 1111 111

30 Observation Glass 60326 1 1 1 1 1 1 1 1111111 1

31 Observation Glass Gasket, Outer 60318 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

32 Observation Glass Holder 60314 1111 1 1111111 111

Ref # Name of Part

Part # 456789101112131415161718

Number of Sections with Item Quantities Below

Page 27

SERIES 28HE BOILER INSTALLATION AND OPERATION INSTRUCTIONS

33 Observation Glass Cover Plate 3420 1 11111111111111

ns Rear Observation Port Hardware 71301 1 1 1 1 1 1 111111111

Burner Mounting Plate Assembly, 9" 70641

Burner Mounting Plate Assembly, 10 1/4" 70640

34(3) Burner Mounting Plate Assembly, 12 1/2" 70510 Burner mounting plate determined by burner selection

Burner Mounting Plate Assembly, 10 1/4" 70672

Burner Mounting Plate Assembly, 7 3/4" 70669

ns Burner Mounting Plate Hardware 71267 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

35 Burner Mounting Plate Insulating Block 69645 1 1 1 1 1 1 1 1 1 1 1 1111

36 Burner Mounting Plate Rope Seal, 3/8 x 7 ft. 76540 1 1111 111 1111 1 11

ns Burner Mtg. Plate Ins. Block Hardware 71268 1 1 11111 1111 1 1 11

37 Operating Control, PA404A 50493 One per steam boiler

38 3 1/2" Steam Gage 60269 One per steam boiler

39 Hi Limit Control, L404C 50494 One per steam boiler

n/s Can of Spray Adhesive 70492 1 1 1 1 1 1 2 2 2 2222 22

n/s Flue Brush 60090 1 1 1 1 1 1 1 1 1 1 11111

(3) Burner mounting plate assembly includes the burner mounting plate with the observation glass and cover.

Ref # Name of Part

Part # 456789101112131415161718

Number of Sections with Item Quantities Below

dizziness

headaches

nausea

vision problems

loss of muscle control

weakness

shortness of breath

unclear thinking

unconsciousness

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:

The symptoms of CO poisoning are often confused with those of influenza, and the highest incidence of poisoning

occurs at the onset of cold weather or during flu season. A victim may not experience any symptoms, only one

symptom, or a few symptoms. Suspect the presence of carbon monoxide if symptoms tend to disappear when

you leave your home.

The following signs may indicate the presence of carbon monoxide:

• Hot gases from appliance, venting system, pipes or chimney, escaping into the living space.

• Flames coming out around the appliance.

• Yellow colored flames in the appliance.

• Stale or smelly air.

• The presence of soot or carbon in or around the appliance.

• Very high unexplained humidity inside the building.

If any of the symptoms of CO poisoning occur, or if any of the signs of carbon monoxide are present, VACATE

THE PREMISES IMMEDIATELY AND CONTACT A QUALIFIED HEATING SERVICE COMPANY OR THE GAS

COMPANY OR THE FIRE DEPARTMENT.

To reduce the risk of CO poisoning, have your heating system “tuned up” by a licensed heating contractor or the

gas company -- preferably before each heating season. Also have the service company check your chimney or

vent pipes for blockage.

Your home should also be adequately ventilated, particularly if you have insulated your home.

ONLY QUALIFIED, LICENSED SERVICE CONTRACTORS

SHOULD PERFORM WORK ON YOUR SMITH BOILER.

WARNING

Install, operate and maintain unit in accordance with manufacturer's instructions to avoid exposure to fuel sub-

stances or substances from incomplete combustion which can cause death or serious illness. The State of

California has determined that these substances may cause cancer, birth defects, or other reproductive harm.

Also, install and service this product to avoid exposure to airborne particles of glasswool fibers and/or ceramic

fibers known to the State of California to cause cancer through inhalation.

In an effort to continually improve our products, Smith reserves the right to make changes without notice.

WESTCAST, INC.

260 NORTH ELM STREET WESTFIELD, MA 01085

TEL. (413) 562-9631 FAX (413) 562-3799