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28-IOM-3
SERIES 28HE
GAS OR OIL STEAM BOILER
INSTALLATION & OPERATING
INSTRUCTIONS
Page 2
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
Steam Boiler Piping .......................................... page 15
Burner Installation ............................................ page 18
Electrical Wiring ................................................ page 19
Boiler Operation............................................... page 19
Boiler Checking & Adjustment .......................... page 20
Boiler Maintenance ........................................... page 21
Water Treatment ............................................... page 21
Repair Parts ..................................................... page 23
Health Warnings ............................................... page 24
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 3 ft, 0.9 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 in. 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
Page 4
Page 5
Page 6
VENT CONNECTIONS
WARNING: Never modify or alter any part of the
boilers 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 in. between
single wall metal vent pipe and all combustible materials.
Page 7
BOILER ASSEMBLY
Locate the boiler installation site based on the guidelines 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 factor y 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
INTER.
SECTION
WASHER ON SIDE TO BE
TORQUED. USE ANTISIZE
ON THREADS
BACK
SECTION
MIN.- FLUSH
MAX. 3/8
FLOOR ANGLE
Page 9
Nm
34
34
34
14
68
68
68
102
102
102
42
169
169
169
169
54
1
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
2
T
H
T
T
T
T
H
H
H
H
H
H
H
H
H
3
H
T
H
H
H
H
T
T
T
T
T
T
T
T
T
4
B
H
T
P
P
P
H
H
H
H
H
H
H
H
H
B
H
T
H
H
P
P
P
P
P
P
P
P
P
B
H
T
P
H
T
T
H
H
H
H
H
H
18
Page 10
2. Screw the four 7/16-14 in. x 2 1/2 in. studs into the
tapped holes in the boiler front section, Figure 9.
Page 11
Page 12
Page 13
Page 14
14
4
7
12
Size
1/8"
3/4"
3/4"
3/4"
3/4"
6
7
8
9
10
11
12
13
14
Steam
Chamber Pressure
Probe LWCO
Water Glass
Manuel Reset High
Limit & Steam Gage
Water Column - Top
Skim Tapping
1"
1 1/2"
3/4"
1 1/2" Inspection Tapping - Top
1"
Water Column - Bottom
3"
Boiler Drain/Blowoff
4"
Return
3"
Safety Valve
Blank Flange
8
2
9
10
11
Page 15
Equalizer
Size, NPT
2 1/2"
2 1/2"
4"
4"
Page 16
Page 17
Page 18
Install 3 in. nipples into the two 3 in. NPT lower tappings
in the front section and install ball valves so the boiler
can be blown down.
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 manufacturers 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.
Page 19
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 Boilers
Follow the burner manufactures lighting instructions
that were supplied with the burner.
ELECTRICAL WIRING
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!
Page 20
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.
Page 21
10. Install the clean out covers and reseal them with a
silicone caulk rated for 500F, 260C.
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
manufactures 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.
WATER TREATMENT
Water treatment is not a boiler requirement it is a system
requirement. If Graphite Port Connectors were used in
the assembly of this boiler, water treatment should not
pose any problem.
Page 22
(1)
16
16A
18
19
NS
20
21
23
24
25
28
29
30
31
32
33
ns
34(3)
ns
35
36
37
38
39
n/s
n/s
41
(1)
Name of Part
Front Section (Flanged Connection)
Steam Blank Flange (Front)
Graphite Port Connector Set
Draw Rod Washers
5/8" x 11" Draw Rods
Draw Rod Hex Nuts
Rope, 1/2" x 12 1/2 feet
Heat Transfer Rod Set (HE only)
Cleanout Cover Assembly
Cleanout Cover Nut
Cleanout Cover Washer
Cleanout Cover Rope Seal, 3/8" x 45"
Cleanout Cover Bolt
Rear Observation Port Assembly
Part #
4
01-3702 1
70-1224 1
60375
3
62099 12
60102 12
60877 24
70660
3
70063
3
70593
3
57-1001 6
62097
6
76538
1
57-4001 6
70614
1
69371
1
Slide Damper
69372
69373
Flue Outlet Increaser, 16" to 18"
69904
Smoke Hood Assembly, 10"
70633
1
Smoke Hood Assembly, 12"
70611
Smoke Hood Assembly, 14"
70612
Smoke Hood Assembly, 16"
70613
Smokehood insulating tape
74301
1
1 1/4" Steam Safety Valve, 15 lb.
61983
1
1 1/2"Steam Safety Valve, 15 lb.
61984
2" Steam Safety Valve, 15 lb.
61985
2 1/2"Steam Safety Valve, 15 lb.
61986
3" Steam Safety Valve, 15 lb.
61987
Back Section
01-3700 1
Steam Blank Flange (Back)
70-1223 1
Intermediate Section w/ 5" Tapping & Boss
3624
Intermediate Section, Plain with Boss
3622
Intermediate Section, Plain w/o Boss
3658
Int. Section w/ Heater Opening w/o Boss
3623
Tankless Cover Plate & Coil Gasket
60327
Tankless Heater, 8 GPM, 30 L/H
50653
Tankless Heater, 12 GPM, 45 L/H
50655
Tankless Cover Plate with Gasket
70628
Gauge Glass, 5/8" x 11 1/2"
61931
Observation Glass Gasket, Inner
60317
1
Observation Glass
60326
1
Observation Glass Holder
60314
1
Observation Glass Gasket, Outer
60318
1
Observation Glass Cover Plate
3420
1
Rear Observation Port Hardware
71301
1
Burner Mounting Plate Assembly, 9"
70641
Burner Mounting Plate Assembly, 10 1/4"
70640
Burner Mounting Plate Assembly, 12 1/2"
70510
Burner Mounting Plate Assembly, 7 3/4"
70669
Burner Mounting Plate Hardware
71267
1
Burner Mounting Plate Insulating Block
69645
1
Burner Mounting Plate Rope Seal, 3/8 x 7 ft. 76540
1
Operating Control, PA404A
50493
3 1/2" Steam Gage
60269
Hi Limit Control, L4079B
50495
Can of Spray Adhesive
70492
1
Flue Brush
60090
1
Stack Thermometer
51383
1
1
1
17
1
1
16
64
64
128
16
16
16
32
32
1
32
1
18
1
1
17
68
68
136
17
17
17
34
34
1
34
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
Section quantities based on model ordered
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
One per steam boiler
One per steam boiler
One per steam boiler
1
2
2
2
2
1
1
1
1
1
1
1
1
1
1
Smokehood assembly includes the smokehood, slide damper, angle bracket and hardware.
Cleanout cover assembly includes the cleanout cover, insulation, rope and mounting hardware.
(3)
Burner mounting plate assembly includes the burner mounting plate with the observation glass and cover.
(2)
16
1
1
15
60
60
120
15
15
15
30
30
1
30
1
1
1
1
1
Page 23
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
1
1
2
1
1
2
1
1
2
1
1
Page 24
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.
WARNING
Install, operate and maintain unit in accordance with manufacturer'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.
In an effort to continually improve our products, Smith reserves the right to make changes without notice.