28A-IOM-7 MEA#273-89-E SERIES 28A 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. TO INSTALLER READ THESE INSTRUCTIONS CAREFULLY. THEY WILL SAVE YOU VALUABLE TIME WHEN ASSEMBLING THE BOILER.
Page 2 SERIES 28A 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 ..........
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 3 Figure 1- Service Clearances to Adjacent Construction WARNING: Never install a 28A 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.
Page 4 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS All Air From Inside The Building If the boiler is to be located in a confined space minimum 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.
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 5 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 28A boilers. The 28A is designed for pressurized operation with a back pressure of 0.10 in, 2.54 mm W.C.
Page 6 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS 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.
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 7 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.
Page 8 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Completed boilers must be tested as follows: 2. 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. Carefully place the back section in position on the angles as shown in Figure 4.
Page 9 SERIES 28A 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. Figure 6 - Section Alignment 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.
Page 10 9. SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS 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. Cleanout Cover Installation 1. The cleanout covers come insulated from the factory.
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 8 - Burner Mounting Plate Details Observation Port Assembly, Figure 9 1. Position the hinged end of the steel flapper door, # 5, over the boss on the observation port cover, # 4. 2. Drive the expansion pin, # 7, through the hinge bosses to secure the door to the cover. 3. Insert the hex bolt, # 6, through the hole in the observation port cover. 4. Install the spring, nut and knob, #"s 3, 2 & 1 on the bolt as shown.
Page 12 SERIES 28A 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. Smokehood Installation, Figure 10 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. 2. Apply smokehood insulation tape to smokehood. Place the observation port cover assembly over the studs and install the washers and nuts.
SERIES 28A 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 11. Figure 11 - Tankless Heater Installation 5. Page 13 Install the operating control in one of the heater mounting plates to ensure quick burner response when there is a demand for hot water.
Page 14 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS GENERAL PIPING REQUIREMENTS Figure 14 - Back Section Tapping Locations 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.
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 15 - Relief & Safely Valve Piping Table 7 - Boiler Water Content Boiler Model Water Boilers Gallons Liters 28A-4 123 466 28A-5 150 568 28A-6 177 670 28A-7 204 772 28A-8 231 875 28A-9 258 977 28A-10 285 1079 28A-11 312 1181 28A-12 339 1283 28A-13 366 1386 28A-14 392 1484 28A-15 419 1586 28A-16 446 1689 28A-17 473 1791 28A-18 500 1893 Page 15 Steam Boilers Gallons Liters 104 394 126 477 148 560 170 644 192 727 214 810 236 893 258 977 280 106
Page 16 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS 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 20.
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 18 Typical Single Water Boiler Piping Figure 19 - Typical Multiple Water Boiler Piping Page 17
Page 18 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 20 - Chilled Medium Diagram NOTE FOR HEATING: VALVES “H” OPEN, VALVES “C” CLOSED. FOR COOLING: VALVES “H” CLOSED, VALVES “C” OPEN. 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.
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 19 Table 9 - Steam Boiler Capacities Minimum Feed Water Condensate Receiver I=B=R Gross Output Evaporation Rate Boiler Pumping Rate Capacity Model MBH kW GPM L/hr GPM L/hr Gallons Liters 28A-S-4 900 264 1.9 7.3 3.9 14.8 37 140 28A-S-5 1166 342 2.5 9.5 5.0 18.9 48 182 28A-S-6 1433 420 3.1 11.7 6.2 23.5 59 223 28A-S-7 1699 498 3.7 13.8 7.3 27.6 69 261 28A-S-8 1965 576 4.2 16.0 8.4 31.8 80 303 28A-S-9 2232 654 4.8 18.1 9.6 36.
Page 20 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 22 - Typical Steam Piping - Gravity Return for Multiple Boilers Figure 23 - Typical Steam Piping - Pumped Return for Multiple Boilers
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 21 Install 3" nipples and ball valves in the two 3" NPT front section tappings so the boiler can be blown down. to prevent injury! If eye or skin contact occurs flush with large quantities of water. 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.
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.
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS 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). Page 23 Hi Limit The aquastat high limit controls the maximum water temperature in the boiler.
Page 24 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS 6. Vacuum out the burner base and clean and inspect all of the components. Replace any damaged or badly corroded parts. Controls 1. Low water cutoff devices must be serviced per the manufacture’s instructions. 7. Inspect the cleanout cover insulation and rope seal. If damaged or deteriorated replace them. 2. 8. Install the clean out covers and reseal them with a silicone caulk rated for 500°F, 260°C. 9.
SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 25 - Boiler Assembly Page 25
Page 26 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Ref # Name of Part Part # 4 Number of Sections with Item Quantities Below 5 6 7 8 9 10 11 12 13 14 15 16 17 1 Front Section 3621 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 Graphite Port Connector Set 60375 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 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
Page 27 SERIES 28A BOILER INSTALLATION AND OPERATION INSTRUCTIONS Ref # ns 34(3) (3) Name of Part Part # 4 Number of Sections with Item Quantities Below 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Rear Observation Port Hardware 71301 1 1 1 1 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, 10 1/4" 70672 1 1 1 1 1 1 1 1 1 1 Burner mounting plate determined by bur
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.