Smith Cast Iron Boilers GS110W User Manual

GS110IOM-2  
GS110W  
NATURAL OR PROPANE GAS BOILERS  
INSTALLATION & OPERATION MANUAL  
MEA#117-96-E  
DESIGNED AND TESTED ACCORDING TO A.S.M.E. BOILER AND PRESSURE  
VESSEL CODE, SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE  
OF 50 PSI WATER.  
TO INSTALLER  
NOTE: READ THESE INSTRUCTIONS CAREFULLY. THEY  
WILL SAVE YOU TIME IN ASSEMBLING BOILER PROPERLY.  
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.  
INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE HEATER.  
CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.  
NOTE: Installation and service must be performed by a qualified installer, service  
agency or the gas supplier.  
260 NORTH ELM STREET WESTFIELD, MA 01085  
TEL. (413) 562-9631 FAX: (413) 562-3799  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Page 3  
The installation must conform to the requirements of the  
2. An optimum site will be level, central to the hot water  
authority having jurisdiction or, in the absence of such  
requirements, to the National Fuel Gas Code, ANSI  
Z223.1-latest revision. In Canada, the installation must  
be in accordance with the requirements of CSA B149.1  
or B149.2 Installation Code for Gas Burning Appliances  
and Equipment.  
piping system, close to an outside wall and have  
adequate fresh air for combustion.  
3. Ensure that the floor is structurally sound and will  
support the weight of the boiler.  
NOTE: This boiler is designed for direct placement  
on a combustible floor. Never install this boiler on  
carpeting!  
BOILER RATINGS & CAPACITIES  
Before undertaking the installation of the GS110 check  
the boiler rating plate to ensure that the boiler is the  
proper size for the job. The "Net I=B=R Ratings" specify  
the equivalent amount of direct cast iron radiation that  
the boiler can handle under normal conditions.  
4. DO NOT install this boiler in a location that would  
subject any of the gas ignition components to direct  
contact with water or excessive moisture during  
operation or servicing.  
Also ensure that the boiler has been set up for the type  
of gas available at the installation site. Other important  
considerations are the availability of an adequate  
electrical supply, fresh air for combustion and proximity  
a suitable outside wall.  
5. NEVER store objects on or around 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 extensive property damage, severe personal  
injury or death!  
BOILER LOCATION  
WARNING: The clearances to combustible  
construction show in Figure 1 must be main-  
tained. Failure to comply with this warning can  
result in extensive property damage, severe  
personal injury or death!  
Figure 2 - Moving Boiler  
CAUTION: Do not lift the boiler by the jacket. Use a  
hand truck under the base frame as shown in Figure 2.  
1. Locate the boiler in an area that provides good  
access to the unit. Keep in mind that servicing may  
require the removal of jacket panels. Accessibility  
clearances must take precedence over fire  
protection clearances.  
Figure 1 - Clearances to Combustible Construction  
Page 4  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
All Combustion Air From Inside The Building  
COMBUSTION AIR & VENTILATION  
Older houses often have enough “leakage” to provide  
an adequate amount of combustion air provided that the  
demand for combustion air is not too great, Figure 3.  
Homes that are relatively new or “tight” will most likely  
require that the combustion be ducted to the boiler from  
outside the building. Any home utilizing other gas  
burning appliances, a fireplace, wood stove or any type  
of exhaust fan must be checked for adequate  
combustion air when all of these devices are in  
operation at one time.  
WARNING: This boiler must be supplied with  
combustion 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  
CSA B149.1 or .2 Installation Code for Gas  
Burning Appliances and Equipment, or  
applicable provisions of the local building  
codes. Failure to provide adequate combustion  
air for this boiler/water heater can result in  
excessive levels of carbon monoxide which can  
result in severe personal injury or death!  
If the boiler is to be located in an alcove, closet or other  
confined space the distances from the boiler and it's  
vent system to all-combustible construction must be  
equal to or greater than the minimum clearances in  
Figure 1. When installed in a closet or confined space  
two permanent openings of equal area adjoining another  
room or rooms having sufficient volume to meet the  
requirements of an unconfined space must be provided,  
Figures 4 & 5. Each opening must have a minimum free  
area of one square inch per 1000 Btu/hr (2200 mm2/  
kW) based on the total input rating of all gas utilization  
equipment in the confined area. Each opening must be  
no less than 100 square inches (64516 mm2) in size.  
The upper opening must be within 12 inches (305 mm)  
of, but not less than 3 inches (76 mm) from, the top of  
the enclosure. The bottom opening must be within 12  
inches (305 mm) of, but not less than 3 inches (76 mm)  
from, the bottom of the enclosure.  
To operate properly and safely this boiler requires a  
continuous supply of air for combustion. NEVER store  
objects on or around the boiler!  
CAUTION: Combustion air contaminated with  
fluorocarbons or other halogenated compounds  
such as cleaning solvents and refrigerants will  
result in the formation of acids in the combustion  
chamber. These acids will cause premature failure  
of the boiler voiding the warranty!  
CAUTION: If the boiler is operated while the building  
is under construction it MUST be protected from  
wood, concrete, sheet rock and other types of dust.  
Failure to properly protect the unit from  
construction dust will damage the unit voiding the  
warranty!  
All Combustion Air From Outside The Building  
When installed in a confined space without the intake  
air option 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 inches (305 mm)  
of, but not less than 3 inches (76 mm) from, the top of  
the enclosure. The bottom opening must be within 12  
inches (305 mm) of, but not less than 3 inches (76 mm)  
from, the bottom of the enclosure.  
Buildings may require the installation of a fresh air duct  
or other means of providing make-up air if the intake  
air option isn't used. Any building utilizing other gas  
burning appliances, a fireplace, wood stove or any type  
of exhaust fan must be checked for adequate  
combustion air when all of these devices are in  
operation at one time. Sizing of an outside air duct must  
be done to meet the requirements of all such devices.  
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 (550 mm2/kW) of the total input rating of  
all of the equipment in the enclosure.  
WARNING: Never operate this boiler in an  
environment subjected to a negative pressure  
unless the air intake is connected to the  
outdoors. Failure to comply with this warning  
can result in excessive levels of carbon  
monoxide causing severe personal injury or  
death!  
Where communicating with the outdoors through hori-  
zontal ducts, each opening shall have a minimum free  
area of 1 in2/2000 Btu/hr (1100 mm2/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. Sizing of an outside air duct must be  
based on the total input rating of all gas utilization  
equipment in the confined space.  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Page 5  
When calculating the free area necessary to meet the  
Table 1 - Combustion Air Duct Sizing  
make-up air requirements of the enclosure,  
consideration must be given to the blockage effects of  
louvers, grills and screens.  
Input Btuh  
1/4Wire  
Screen Mesh  
Input Btuh  
Metal  
Louvers  
Input Btuh  
Wooden  
Louvers  
FreshAir  
Duct Size  
3” x 12”  
144,000  
256,000  
384,000  
512,000  
108,000  
192,000  
288,000  
384,000  
36,000  
64,000  
96,000  
128,000  
8” x 8”  
Screens must have a minimum mesh size of 1/4"  
(6.4mm). If the free area through a louver or grill is not  
known ducts should be sized per Table 1.  
8” x 12”  
8-1/2” x 16”  
Figure 3 - Horizontal Positive Pressure Venting Using Inside Combustion Air (Cat. III)  
Figure 4 - Vertical Negative Pressure Masonry Chimney System Using Inside Combustion Air (Cat. I)  
Page 6  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Figure 5 - Vertical Negative Pressure Metal Chimney System and Inside Combustion Air (Cat. I)  
Intake Air Option - General Guidelines  
Table 2 - Combustion Air System Sizing  
This configuration provides combustion air directly to the  
boiler using a dedicated pipe. Combustion air can be  
drawn in horizontally through an outside wall or vertically  
through the roof, see Figures 6, 7, 8, 9 & 10.  
Equivalent Intake  
Length (see note)  
3” Diameter  
Equivalent Intake  
Length (see note)  
4” Diameter  
Boiler  
Model  
Number  
GS110-3  
GS110-4  
GS110-5  
GS110-6  
GS110-7  
45 feet (13.7 m)  
45 feet (13.7 m)  
45 feet (13.7 m)  
n/a  
65 feet (19.8 m)  
65 feet (19.8 m)  
65 feet (19.8 m)  
* 40 feet (12.2 m)  
* 40 feet (12.2 m)  
WARNING: Each boiler must have it's own intake  
air system. Common intake air systems are not  
to be used! Improper installation can result in  
excessive levels of carbon monoxide which can  
cause severe personal injury or death!  
n/a  
* 4" to 3" reducer required.  
Note: Subtract 5 feet (1.5 m) for each 90° elbow.  
Single wall galvanized smoke pipe, single wall aluminum  
pipe, flexible aluminum pipe, PVC or CPVC pipe can be  
used for the intake air pipe. Maximum intake lengths  
must not be exceeded per Table 2, larger diameters may  
be used on 3,4,and 5 section boilers.  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Page 7  
All joints in metal intake air systems must be secured  
Intake Air Optional - Horizontal Guidelines  
using corrosion resistant fasteners and sealed using a  
suitable Silicone caulk. If PVC or CPVC is used, the  
joints must be cleaned with a suitable solvent and  
connected using a solvent based PVC cement. The  
intake air system MUST be supported by the building  
structure not the boiler/water heater.  
The maximum equivalent length for the horizontal intake  
air pipe is listed in Table 2. The intake air system must  
be pitched down, toward the terminal, 1/4" per foot  
(21 mm per meter).  
If horizontal runs exceed 5 feet (1.5 m) they must be  
supported at 3 foot (0.98 m) intervals with overhead  
hangers. Figures 7 through 10 show the four horizontal  
air intake options. The intake terminations certified for  
use the GS110 are listed in Table 5.  
Intake Air Option - Vertical Guidelines  
A listed, nonrestrictive intake air cap must be used. The  
intake air cap must terminate as shown in Figure 6. The  
penetration point in the roof must be properly flashed  
and sealed.  
Figure 6 - Vertical Positive Pressure Venting with Outdoor Combustion Air (Cat. III)  
Page 8  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Figure 7 - Horizontal Positive Pressure Venting with Outdoor Combustion Air  
Figure 8 - Horizontal Positive Pressure Venting with Outdoor Combustion Air  
Smith  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Page 9  
Figure 9 - Vertical Negative Pressure Masonry Chimney System using Outside Combustion Air (Cat. I)  
Figure 10 - Vertical Positive Pressure Venting using Outside Combustion Air (Cat. III)  
Page 10  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Certified vent systems are manufactured by the following  
companies:  
GENERAL VENTING GUIDELINES  
Heat-fab, Inc.  
WARNING: The vent installation must be in  
130 Industrial Blvd., Turners Falls, MA 01376  
(800) 772-0739.  
accordance with Part 7, Venting of Equipment,  
of the National Fuel Gas Code, ANSI Z223.1/  
NFPA 54-latest revision or applicable provisions  
of the local building codes. Canadian  
installations must comply with CSA B149.1 or  
.2 Installation Code. Improper venting can result  
in excessive levels of carbon monoxide which  
can result in severe personal injury or death!  
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: Thimbles and fire-stops must be  
used where required. A minimum clearance of  
6" must be maintained between single wall  
metal vents and combustible construction or a  
fire resulting in severe personal injury or death  
may occur!  
GENERAL DIRECT VENT INFO  
In this configuration the boiler blower is used to push the  
flue products to the outdoors while drawing combustion  
air from the outdoors. The instructions under the  
COMBUSTION AIR & VENTILATION SECTION must be  
followed! The vent system must be sized per Table 3.  
WARNING : Each boiler/water heater must have  
it's own vent system. Common positive  
pressure vent systems are not to be used!  
Improper installation can result in excessive  
levels of carbon monoxide which can cause  
severe personal injury or death!  
Table 3 - Positive Pressure Vent System Sizing  
Equivalent Vent  
Length (see note)  
3” Diameter  
Equivalent Vent  
Length (see note)  
4” Diameter  
Boiler  
Model  
Number  
GS110-3  
GS110-4  
GS110-5  
GS110-6  
GS110-7  
45 feet (13.7 m)  
45 feet (13.7 m)  
45 feet (13.7 m)  
n/a  
*65 feet (19.8 m)  
*65 feet (19.8 m)  
*65 feet (19.8 m)  
40 feet (12.2 m)  
40 feet (12.2 m)  
All vent systems must be fully supported by the building  
structure and not by the boiler/water heater.  
n/a  
* 4" to 3" reducer required  
Note: Subtract 5 feet (1.5 m) for each 90° elbow.  
VENT SYSTEM OPTIONS  
The GS110 may be vented the following ways:  
1) Direct Vent (Positive Pressure), uses a vent system  
certified to UL 1738 for installations in the United States,  
ULS636 for installations in Canada. Combustion air is  
piped from the outdoors to the blower inlet.  
HORIZONTAL DIRECT VENT  
SYSTEMS  
See figures 7 & 8. The vent materials used in horizontal  
positive pressure vent systems must be certified to UL  
1738 for installations in the United States, ULS636 for  
installations in Canada.  
2) Horizontal Vent (Positive Pressure), uses a vent  
system certified to UL 1738 for installations in the United  
States, ULS636 for installations in Canada. Combustion  
air is obtained from the space in which the unit is installed.  
Each 90° elbow is equal to 5 linear feet (1.5 m) of pipe.  
To maximize the performance of single wall sheet metal  
vent systems locate 90° elbows as far from the boiler as  
possible and from one another. For best results, horizontal  
vent systems should be as short and straight as possible.  
The vent system must be both gas tight and watertight.  
All seams and joints in metal pipes must be joined and  
sealed in accordance with the vent system manufacturer’s  
instructions.  
3) Vertical Vent (Positive Pressure), uses a vent system  
certified to UL 1738 for installations in the United States,  
ULS636 for installations in Canada. Combustion air is  
piped from the outdoors to the blower inlet or is obtained  
from the space in which the unit is installed.  
4) Vertical/Chimney Vent (Negative Pressure), uses an  
approved metal chimney system or masonry chimney.  
Combustion air is obtained from the space in which the  
unit is installed or is piped from the outdoors to the blower  
inlet.  
When horizontal vent runs exceed 5 feet (1.5m) they must  
be supported at 3 foot (0.98 m) intervals with overhead  
hangers. The vent system must be pitched down, toward  
the vent terminal, 1/4" per foot (21mm per meter). If any  
part of a single wall metal vent system passes through  
an unheated space it must be insulated with insulation  
rated for 400°F. Structural penetrations must be made  
using approved thimbles.  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Page 11  
Horizontal vent systems shall terminate at least 4 feet  
HORIZONTAL VENT  
(1.3 m) below, 4 feet (1.3 m) horizontally from or 1 foot  
(0.23 m) above any door, window or gravity air inlet into  
any building. It must not terminate less than 4 feet (1.3  
m) horizontally from, and in no case above or below,  
unless a 4 feet (1.3 m) horizontal distance is maintained,  
from electric meters, gas meters, regulators and relief  
equipment and not less than 7 feet (2.3 m) from any  
adjacent public walkway. The bottom of the vent  
terminal(s) shall be located at least 5 feet (1.5 m) above  
the air intake terminal(s). Avoid terminal locations likely  
to be affected by winds, snowdrifts, people and pets.  
POSITIVE PRESSURE SYSTEMS  
See Figure 3. The vent materials used in horizontal  
positive pressure vent systems must be certified to UL  
1738 for installations in the United States, ULS636 for  
installations in Canada.  
The maximum vent lengths are listed in Table 3.  
Each 90° elbow is equal to 5 linear feet (1.5 m) of pipe.  
To maximize the performance of single wall sheet metal  
vent systems locate 90° elbows as far from the boiler  
as possible and from one another. Horizontal vent  
systems should be as short and straight as possible.  
Table 4 - Certified Vent & Intake Terminals  
Company  
Protech  
Part No.  
300311  
Description  
Tee  
Dia. (in.)  
3
4
3
4
3
4
3
4
3
4
3
4
When horizontal vent runs exceed 5 feet (1.5 m) they  
must be supported at 3 foot (0.98 m) intervals with  
overhead hangers. The vent system must be pitched  
down, toward the vent terminal, 1/4" per foot (21 mm  
per meter). If any part of a single wall metal vent system  
passes through an unheated space it must be insulated  
with insulation rated for 400°F. Structural penetrations  
must be made using approved thimbles.  
Protech  
300312  
Tee  
Protech  
300186  
Bird Screen  
Bird Screen  
45° Elbow  
45° Elbow  
90° Elbow  
90° Elbow  
Mitered  
Mitered  
Tee  
Protech  
300187  
Protech  
300130  
Protech  
300131  
Protech  
300160  
Protech  
300161  
Heat-Fab  
Heat-Fab  
Heat-Fab  
Heat-Fab  
Heat-Fab  
Heat-Fab  
Heat-Fab  
Heat-Fab  
7390GC  
7490GC  
7390TEE  
7490TEE  
7392GC  
7492GC  
7314TERM  
7414TERM  
The vent system must be both gas tight and watertight.  
All seams and joints in metal pipes must be joined and  
sealed in accordance with the vent system  
manufacturer's instructions.  
Tee  
Screen  
Screen  
90° Elbow  
90° Elbow  
3
4
Horizontal vent systems shall terminate at least 4 feet  
(1.3 m) below, 4 feet (1.3 m) horizontally from or 1 foot  
(0.23 m) above any door, window or gravity air inlet into  
any building. It must not terminate less than 4 feet (1.3  
m) horizontally from, and in no case above or below,  
unless a 4 feet (1.3 m) horizontal distance is maintained,  
from electric meters, gas meters, regulators and relief  
equipment and not less than 7 feet (2.3 m) from any  
adjacent public walkway. The bottom of the vent  
terminal(s) shall be located at least 5 feet (1.5 m) above  
the air intake terminal(s). Avoid terminal locations likely  
to be affected by winds, snowdrifts, people and pets.  
Protect building materials and vegetation from  
degradation caused by flue gasses.  
VERTICAL DIRECT VENT SYSTEMS  
See Figures 6 & 10. The vent materials used in vertical  
positive pressure vent systems must be certified to UL  
1738 for installations in the United States, ULS636 for  
installations in Canada.  
The maximum length for the vertical vent system is  
listed in Table 4. Each 90° elbow is equal to 5 linear  
feet (1.5 m) of pipe. To maximize the performance of  
single wall sheet metal vent systems locate 90° elbows  
as far from the boiler as possible and from one another.  
If any part of a single wall metal vent system passes  
through an unheated space it must be insulated with  
insulation rated for 400°F. Structural penetrations must  
be made using approved fire-stops.  
Table 5- Certified Vent Terminals  
Company  
Protech  
Part No.  
300311  
Description  
Tee  
Dia. (in.)  
3
4
3
4
3
4
3
4
3
4
The vent system must be both gas tight and watertight.  
All seams and joints in metal pipes must be joined and  
sealed in accordance with the vent system  
manufacturer’s instructions.  
Protech  
300312  
Tee  
Protech  
300130  
45° Elbow  
45° Elbow  
90° Elbow  
90° Elbow  
Tee  
Protech  
300131  
Protech  
300160  
Protech  
300161  
Vertical vent systems must be terminated with an  
approved terminal cap as shown in Figures 6 & 10.  
Heat-Fab  
Heat-Fab  
Heat-Fab  
Heat-Fab  
7390TEE  
7490TEE  
7314TERM  
7414TERM  
Tee  
90° Elbow  
90° Elbow  
Page 12  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
VERTICAL VENT  
WARNING: If an appliance using any type of a  
mechanical draft system operating under  
positive pressure is connected to a chimney  
flue, never connect any other appliances to this  
flue. Doing so can result in excessive levels of  
carbon monoxide which can cause severe  
personal injury or death!  
POSITIVE PRESSURE SYSTEMS  
See Figure 11. The vent materials used in vertical  
positive pressure vent systems must be certified to UL  
1738 for installations in the United States, ULS636 for  
installations in Canada.  
The maximum vent lengths are listed in Table 3.  
Chimney Inspection & Sizing  
A thorough inspection of the masonry chimney must be  
performed to ensure that the chimney is clean, properly  
constructed and properly sized. Exterior masonry  
chimneys should not be used unless properly lined to  
prevent condensation and draft problems. Table 6 lists  
the equivalent breeching and flue sizes required for the  
boiler/water heater. 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  
of the appliances.  
Each 90° elbow is equal to 5 linear feet (1.5 m) of pipe.  
To maximize the performance of single wall sheet metal  
vent systems locate 90° elbows as far from the boiler  
as possible and from one another. If any part of a single  
wall metal vent system passes through an unheated  
space it must be insulated with insulation rated for 400  
°F. Structural penetrations must be made using  
approved fire-stops.  
The vent system must be both gas-tight and watertight.  
All seams and joints in metal pipes must be joined and  
sealed in accordance with the vent system  
manufacturer's instructions. Vertical vent systems must  
terminate as shown in Figures 6 & 11. An approved  
terminal cap must be used.  
Table 6 - Equivalent Breeching & Chimney Size  
Boiler  
Model  
Vent & Chimney Diameter  
inches (mm)  
Intake Diameter  
inches (mm)  
GS110-3  
GS110-4  
GS110-5  
GS110-6  
GS110-7  
3 (7.6)  
4 (10.2)  
4 (10.2)  
5 (12.7)  
5 (12.7)  
3 (7.6)  
3 (7.6)  
3 (7.6)  
4 (10.2)  
4 (10.2)  
VERTICAL VENT  
NEGATIVE PRESSURE SYSTEMS  
See Figures 4, 5 & 9. The GS110 is listed as a Category  
I appliance when vented vertically into a metal chimney  
system or masonry chimney sized as listed in Table 6.  
Note: These sizes are based on a 20 foot (6.1m)  
chimney height.  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Page 13  
The vent connector should be sloped up toward the  
Always provide a minimum clearance of 6 inches  
chimney 1/4" per foot. Ensure that the vent connector  
is properly supported and each connection securely  
fastened with at least 3 corrosion resistant sheet metal  
screws. The termination of the vent pipe must be flush  
with the inside of the chimney flue.  
between single wall metal vent pipe and any  
combustible materials. Type B1 vent may be used,  
clearance between it and any combustible material must  
be as listed.  
WARNING: Failure to maintain minimum  
clearances between vent connectors and  
combustible materials can result in a fire  
causing extensive property damage, severe  
personal injury or death!  
CAUTION: The vent connector length must never  
exceed 3/4 of the height of the chimney or venting  
problems will occur!  
Figure 11 - Vertical Positive Pressure Venting (Cat. III)  
Page 14  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Dans la mesure du possible, fermer toutes les  
COMMON VENT SYSTEMS  
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.  
WARNING: DO NOT connect this boiler or any  
other appliance using a positive pressure  
common vent system or a mechanical draft  
system! Failure to comply with this WARNING  
could result in the accumulation of carbon  
monoxide gas which can cause severe personal  
injury or death!  
If an existing boiler/water heater 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/water heater, 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.  
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.  
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 fonction-  
nent pas: système d'évacuation  
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 coupe-tirage 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.  
a) Seal any unused openings in the common venting  
system.  
Sceller toutes les ouvertures non utilisées du sys-  
tème d'évacuation.  
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.  
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'évacu-ation  
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.  
Une fois qu'il a été d éterminé, selon la métode  
indiquée ci-dessus, 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.  
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.  
g) Any improper operation of the common 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.  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Tout mauvais fonctionnement du systéme d'évacu-  
Page 15  
WARNING: Failure to connect a condensate trap  
or pump to the flue collector can result in  
excessive levels of carbon monoxide which can  
cause severe personal injury or death!  
tion 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'in-  
stallation CSA-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.  
HEATING SYSTEM PIPING  
CAUTION: All heating system piping must be  
installed in accordance with the ANSI/ASME Boiler  
and Pressure Vessel Code, Section IV. All applicable  
local codes and ordinances must also be followed.  
If the boiler is installed above any radiation  
elements it must be fitted with a low water cutoff  
device installed above the normal boiler water level!  
CONDENSATE PIPING  
A small amount of condensate is generated on start up.  
To prevent an excess amount of condensate collecting  
in the flue collector a condensate drain has been  
provided. A condensate trap or pump MUST be  
connected to the condensate fitting in the bottom of the  
flue collector.  
The GS110 hot water boiler comes from the factory  
ready to be piped to the heating system. Each boiler is  
equipped with a safety relief valve which must be piped  
in accordance with the ANSI/ASME Boiler and Pressure  
Vessel Code, Section IV, see Figure 13.  
A trap can be made by tie wrapping a 4” loop in a piece  
of vinyl hose attached to the condensate drain fitting.  
The trap must be filled with water to prevent flue  
gassses from escaping, see Figures 12 A and B.  
Table 7 - Boiler Water Volume  
Boiler  
Model  
Water Volume  
Gallons  
1.8  
Liters  
6.8  
A condensate hose has been supplied with  
boiler and is located inside the literature bag.  
Installing contractor will have to continue the  
run of condensate to a nearby drain or pump.  
GS110-3  
GS110-4  
GS110-5  
GS110-6  
GS110-7  
2.4  
9.1  
3.0  
11.4  
13.6  
15.9  
3.6  
4.2  
Figure 12A- Condensate Trap  
* 1-1/2 " Supply and Return Tappings  
Figure 13 - Relief Valve Piping  
Figure 12B- Condensate Trap  
SIOM-75  
Page 16  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Ensure that the boiler is level from front to back and  
from side to side. Use metal shims to level the boiler.  
NEVER use combustible materials for shims.  
Pump Away Bypass  
The system bypass shown in Figure 15 should be used  
on single zone systems, or multiple zone systems using  
zone valves, when the circulator is installed in the supply  
piping. The bypass must be installed between the supply  
and return pipes on the pressure side of the circulator.  
Bypass Piping  
CAUTION: Never connect this boiler directly to a  
large volume system, in-floor radiant system, snow  
melt system or any other system that would cause  
the steady state water temperature in the boiler to  
drop below 140°F. To prevent damage due to  
excessive condensation, one of the following piping  
options must be used or the boiler warranty will be  
voided!  
Figure 15 - Pump Away Bypass Piping  
CAUTION: The blend pump arrangement shown in  
Figure 16 must be used when the flow from any  
zone in a multiple zone system is less than 4 GPM  
or boiler short cycling on the high limit will occur!  
For the three systems listed below, adjust the bypass  
valve to divert some of the heated water back into the  
boiler's return piping. When adjusted correctly the  
temperature of the boiler water will exceed 140°F within  
five minutes of a warm start. A plug valve should be  
used as the bypass valve for best system performance.  
NOTE: Some of the circulator's capacity will be used  
in the blending process for the first two systems.  
Large heating systems may require a larger  
circulator.  
Pumped Blend Bypass  
The system bypass shown in Figure 16 should be used  
on multiple zone systems. The bypass must be installed  
between the supply and return pipes on the suction side  
of the zone circulators. The bypass valve must be  
installed on the pressure side of the bypass circulator.  
System Bypass  
The system bypass shown in Figure 14 should be used  
on single zone systems, or multiple zone systems using  
zone valves, when the circulator is installed in the return  
piping. The bypass must be installed between the supply  
and return pipes on the suction side of the circulator.  
Figure 16 - Pumped Bypass Piping  
Figure 14 - System Bypass Piping  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Page 17  
Figure 17 - TACO 007 Performance Curve  
Piping For Use With Cooling Units  
The boiler, when used in connection with a refrigera-tion  
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.  
10  
8
6
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.  
4
Circulators  
TACO 007 CIRCULATOR  
PERFORMANCE CURVE  
The TACO 007 circulator supplied with the boiler is sized  
for use in a closed heating system with a 30 psi  
maximum operating pressure. If the 007 circulator does  
not have the required capacity for the system in which  
it is to be installed, an extra zone circulator or a higher  
capacity circulator will be needed. Figure 17 depicts the  
performance curve for the TACO 007 circulator.  
2
0
0
5
10  
15  
20  
25  
FLOW - GPM  
Page 18  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
ormance criteria were met  
Safe lighting and other perf  
GAS SUPPLY PIPING  
ly provided on  
with the gas manifold and control assemb  
The GS110 hot water boiler comes from the factory  
ready to be piped to the gas supply. The gas supply can  
be piped from the left or right side of the boiler.  
GS110  
the boiler when the boiler underwent tests specified in  
ANSI Z21.13. All gas connections MUST be leak tested  
ation.  
before putting the boiler into oper  
Section  
Size  
Connection  
Tapping  
Table 8 - Gas Pipe Capacity  
Pipe length in feet  
40 50 60  
Gas pipe Capacity (ft3/hr)  
278 190 152 130 115 105 90  
Nominal  
Iron Pipe  
Size, (in)  
1/2"  
1/2"  
1/2"  
3/4"  
3/4"  
3
4
5
6
7
10  
20  
30  
80 100 150  
3
79 64  
/4  
520 350 285 245 215 195 170 150 120  
1050 730 590 500 440 400 350 305 250  
1600 1100 890 760 670 610 530 460 380  
1″  
11/4  
11/2  
If for any reason the boiler is not for the type of gas  
available at the installation site, call the nearest Smith  
Cast Iron Boiler distributor to resolve the problem.  
Note: Maximum pipe capacity in ft3/hr is based on a 0.60 specific  
gravity gas at a pressure of 0.5 psig and a 0.3" WC pressure drop.  
Figure 18 depicts the proper way to connect the boiler  
to the gas supply piping. The manual shut-off valve  
MUST be installed in the supply piping. It should be  
approximately 5 feet above the floor. Provide a sediment  
trap/drip leg at the bottom of the vertical section of the  
gas supply pipe. A ground joint union should be installed  
between the boiler gas controls and the supply piping.  
Each of these items is needed to ensure long life and  
ease of servicing. Always use a pipe sealant that is  
suitable for use with LP gas.  
t
Table 9 - Equivalent Pipe Length Char  
Type of pipe fitting  
Nominal  
Iron Pipe  
Size, (in)  
Tee  
Gas Valve  
(full port)  
90° Elbow  
Gas Cock  
(branch flow)  
Equivalent length of pipe fitting in feet  
3
2.6  
3.5  
4.0  
5.2  
5.2  
6.9  
0.6  
0.8  
0.9  
1.2  
1.5  
1.9  
2.3  
3.0  
/
4
1″  
11/4  
11/2  
8.0  
10.3  
Whenever the gas supply piping is pressure tested the  
Figure 18 - Gas Supply Piping  
ust be protected. If the test pres-  
boiler gas controls m  
a) isolate  
sure is equal to, or less than 1/2 psig (3.5 kP  
ual shut off valve, see  
the boiler by closing it's man  
Figure 18. If the test pressure is greater than 1/2 psig  
(3.5 kPa), disconnect the boiler and it's individual shut-  
off valve from the gas supply piping.  
or  
WARNING: Never use an open flame to test f  
ved leak  
ys use an appro  
gas leaks. Alwa  
Failure to comply with this  
detection method.  
xplosion!  
WARNING could result in an e  
WIRING  
ELECTRICAL  
CAUTION: Label all wires prior to disconnection  
ols. Wiring errors can cause  
when servicing contr  
erous operation!  
improper and dang  
ATTENTION: Au moment de l'entretien des  
vant de les  
CAUTION: Always use a wrench on the gas valve  
body when making gas connections to it. Never  
over-tighten the piping entering the gas valve body  
or the gas valve will be damaged!  
commandes, étiquetez tous les fils a  
s de câblage peuvent  
débrancher. Des erreur  
entraîner un fonctionnement inadéquat et  
onctionne  
dangereux. S'assurer que l'appareil f  
ois l'entretirn terminé.  
adéquatement une f  
Table 8 should be used to ensure that the gas supply  
piping is sized properly. If more than one appliance is  
supplied by the same supply pipe, the piping must be  
sized based on the maximum possible demand. Do not  
neglect the pressure drop due to pipe fittings. Table 9  
should be used in conjunction with Table 8 to ensure  
that the gas supply piping is sized properly.  
The electrical connections to this boiler/water heater  
must be made in accordance with all applicable local  
ical  
vision of the National Electr  
codes and the latest re  
Code, ANSI /NFPA-70.  
orm  
Installation should also conf  
with CSA C22.1 Canadian Electrical Code Part I if  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Page 19  
installed in Canada. Install a separate 120 volt 15 amp  
Once the flame has been proven, the system is in  
circuit for the boiler. A properly rated 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.  
Steady-State heating mode. The control will continuously  
monitor the thermostat, limit switch, pressure switch, and  
flame sense. If the thermostat opens, the control will  
de-energize the gas valve and begin post-purge. If the  
limit switch opens, the control will de-energizes the gas  
valve, run through post-purge, and wait for the limit  
switch to re-close before attempting re-ignition. If flame  
is lost, the control will de-energize the gas valve, run  
through post-purge, and go to pressure switch proving  
mode for re-ignition. If the pressure switch opens for  
more than 0.1 seconds the inducer is turned off for 30  
seconds, then the control goes to the pressure switch  
proving mode for a re-ignition attempt.  
Line voltage field wiring of any controls or other devices  
must use copper conductors with a minimum size of #14  
awg. Low voltage wiring must not be less than #18 awg  
with a neoprene, thermoplastic or other equivalent  
insulation having a minimum insulation thickness of  
0.012 inches.  
Refer to Figures 19A and 19B for proper wiring  
connections.  
When the thermostat is satisfied the post purge period  
starts. A post-purge will be performed at any time the  
gas valve has been on and is turned off, except for loss  
of pressure switch, when a post-purge would be  
ineffective. The post-purge must be completed before a  
new ignition sequence can start.  
Thermostat Installation  
ALWAYS follow the instructions included with the ther-  
mostat to be used to control the boiler. Proper location  
of the thermostat will ensure efficient trouble-free  
operation of the boiler. Mount the thermostat to an inside  
wall at a height approximately five feet above the floor.  
Avoid placing the thermostat in areas that will not pro-  
vide an accurate measurement of the room temperature.  
Locating the thermostat behind a door, in an alcove,  
close to a source of thermal radiation or in a drafty area  
will cause poor or sporadic heating.  
In the event that the flame signal is lost after the flame  
has been proven, the system will turn off the gas valve  
within 2.0 seconds, perform the post-purge, and repeat  
the ignition sequence. As a preventative measure to  
avoid nuisance shutdown due to a flickering flame, the  
flame must be lost for a minimum of 0.5 seconds.  
Control Outputs:  
Induced draft blower - 1.75 Amps @ 120 VAC.  
OPERATIONAL SEQUENCE  
The control energizes the circulator motor when the  
thermostat contacts are closed. The control then checks  
that the limit switch is closed, if not the control will wait  
for the limit switch to close. With the limit switch closed  
the pressure switch contacts are checked. If the  
pressure switch contacts are open the blower motor is  
energized. If the pressure switch contacts aren’t open  
the control will wait 45 seconds then lock out. The  
PURGE light will flash to indicate a pressure switch fault.  
Also, if the pressure switch does not close within 5  
minutes of the blower being turned on, the control will  
lock out with the PURGE light flashing to indicate a  
pressure switch fault.  
Circulator Pump - 2.7 Amps @ 120 VAC.  
Hot Surface Igniter - 5.0 Amp resistive @ 120 VAC.  
Gas Valve - 0.6 Amp @ 24 VAC, 0.45 power factor.  
The pre-purge period begins when the pressure switch  
contacts close. At the end of the pre-purge period, the  
control energizes the HSI igniter for an HSI warm-up  
period. This condition will be indicated by illumination of  
the IGNITER light. A one second trial for ignition will take  
place. In the event ignition is not achieved by the end of  
the first trial for ignition period, the control will run through  
a post purge and then de-energize the inducer. When  
the pressure switch contacts open the control will begin  
a new ignition sequence. Failure to establish flame after  
the third attempt will result in ignition lock-out and the  
VALVE light on the control will flash.  
Page 20  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Figure 19A - Wiring Connection Diagram  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Page 21  
Figure 19B - Wiring Ladder Diagram  
B
Page 22  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
FORYOUR SAFETY READ BEFORE OPERATING  
WARNING: If you do not follow these instrucitons exactly, a fire or explosion may result  
causing property damage, personal injury or loss of life.  
A. This appliance does not have a pilot. It is  
• If you cannot reach your gas supplier, call the fire  
department.  
equipped with an ignition device which  
automatically lights the burner. Do not try to light  
the burner by hand.  
C. Use only your hand to push in or turn the gas  
control knob. Never use tools. If the knob will not  
push in or turn by hand, don't try to repair it, call  
a qualified service technician. Force or attempted  
repair may result in a fire or explosion.  
B. BEFORE OPERATING smell all around the  
appliance area for gas. Be sure to smell next to  
the floor because some gas is heavier than air  
and will settle on the floor.  
D. Do not use this appliance if any part has been  
under water. Immediately call a qualified service  
technician to inspect the appliance and to replace  
any part of the control system and any gas control  
that has been under water.  
WHAT TO DO IF YOU SMELL GAS  
• Do not try to light any appliance.  
• Do not tough any electric switch; do not use any  
phone in your building.  
• Immediately call your gas supplier from a neighbor's  
phone. Follow the gas suppliers instructions.  
OPERATING INSTRUCTIONS  
1. STOP! Read the safety information above.  
2. Turn off all electric power to the appliance.  
3. Set the thermostat to lowest setting.  
5. Remove control access panel.  
6. Turn the gas control knob clockwise  
to the  
full “OFF” position, on the White Rodgers 36E  
push the knob before turning it.  
4. This appliance is equipped with an ignition device,  
which automatically lights the burner. Do not try  
to light the burner by hand!  
7. “Wait five (5) minutes** to clear out any gas. Then  
smell for gas, including near the floor. If you smell  
gas, STOP! Follow “B” in the safety information  
above (to the left) on this label. If you don't smell  
gas, go to the next step.”  
8. Turn the gas control knob counterclockwise  
to “ON”.  
9. Replace control access panel.  
10. Turn on all electric power to the appliance.  
11. Set thermostat to desired setting.  
12. If the appliance will not operate, follow the  
instructions “TO TURN OFF GAS TO  
APPLIANCE” and call your service technician or  
gas supplier.  
TO TURN OFF GAS TO APPLIANCE  
1. Turn off all electric power to the appliance.  
2. Set the thermostat to lowest setting.  
3. Remove control access panel.  
4. Push in gas control knob slightly and turn  
clockwise  
to “OFF”. Do not force.  
5. Replace control access panel.  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Page 23  
POUR VOTRE SÉCURITÉ LISEZ AVANT DE METTRE EN MARCHE  
AVERTISSEMENT. Quinconque ne respecte pas à la lettre les instructions dans la présente  
notice risque de déclencher un incendie ou une explosion entraînant des dommages, des  
blessures ou la mort.  
• Si vous ne pouvez rejoindre le fournisseur, appelez  
le service de incendies.  
A. Cet appareil ne comporte pas de veilleuse. Il est  
muni d'un dispositif d'allumage qui allume  
automatique la brûleur. Ne tentez pas d'allumer  
la brûleur manuellement.  
C. Ne poussez ou tournez la maneette d'admission  
du gaz qu'à la main; ne jamais utiliser d'outil. Si  
la manette reste coincée ; ne pas tenter de la  
réparer; appelez un technicien qualifié. Le fait de  
forcer la manette ou de la réparer peut déclencher  
une explosion ou un incendie.  
B. AVANT DE FAIRE FONCTIONNER, reniflez tout  
autour de l'appareil pour déceler une odeur de  
gaz. Reniflez près du plancher, car certains gaz  
sont plus lourds que l'air et peuvent s'accumuler  
au niveau du sol.  
D. N'utilisez pas cet appareil s'il a été plongé dans  
l'eau, même partiellement. Faites inspecter  
l'appareil par un tecnicien qualifié et remplacez  
toute partie du système de contrôle et toute  
commande qui ont été plongés dans l'eau.  
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ  
• Ne pas tenter d'allumer d'appareil.  
• Ne touchez à aucun interrupteur; ne pas vous servir  
des téléphones se trouvant dans le bâtiment.  
• Appelez immédiatement votre fournisseur de gaz  
depuis un voisin. Suives les instructions du  
fournisseur.  
INSTRUCTIONS DE MISE EN MARCHE  
1. ARRÊTEZ! Lisez les instructions de sécurité sur  
la portion supérieure de cette étiquette.  
7. <<Attendre cinq (5) minutes** pour laisser  
échapper tout le gaz. Reniflez tout autour de  
l'appareil, y compris près du plancher, pour  
déceler une odeur de gaz. Si vous sentez une  
odeur de gaz, ARRÊTEZ! Passez à l'étape B des  
instructions de sécurité sur la portion supérieure  
(à gauche) de cette étiquette. S'il n'y a pas  
d'odeur de gaz, passez à l'étape suivante.>>  
2. Mette le thermostat à la température la plus  
basse.  
3. Coupez l'alimentation électrique de l'appareil.  
4. Cet appareil est équipé d'un dispositif d'allumage  
automatique la brûleur.  
8. Tourner le bouton de commande de gaz vers la  
gauche  
, en position de marche “ON”.  
9. Replacer le panneau de parte du réchauffer.  
10. Rétablìr toute l'alimentation électrique de la  
chaudiere.  
11. Mette le thermostat thermostat sur le régleage  
désiré.  
5. Enlever le panneau de parte du réchauffer.  
12. Si l'appareil ne fonctionné pas, voir les instructions  
de “COÙPURE DE L'ARRIVE DE GAZ A LA  
CHAUDIERE” et appeler un technicien reparateur  
ou le fournisseur de gaz.  
6. Tourner le bouton de commande de gaz vers la  
droite  
, en position d'arrêt “OFF”. Ne pas  
forcer!  
COÙPURE DE L'ARRIVE DE GAZ A LA CHAUDIERE  
1. Mette le thermostat à la température la plus basse.  
4. Tourner le bouton de commande de gaz vers la  
droite  
forcer!  
, en position d'arrêt "OFF". Ne pas  
2. Si un entretien doit être effectué, coupez  
l'alimentation électrique de l'appareil.  
5. Replacer le panneau de parte du réchauffer.  
3. Lever le panneau de parte du réchauffer.  
Page 24  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
B. Read, understand and follow the operating  
instructions, on pg. 22 of this manual.  
BOILER SET UP  
NOTE: Before starting the boiler, turn off the  
C. Raise the thermostat at least 5 degrees above the  
room temperature. A delay of about 30 seconds will take  
place as the silicon carbide ignitor heats up. Once the  
ignitor is hot, the main gas valve will open and the burner  
should light. If the burner fails to light the system will  
make two more ignition attempts. If the burner lights, but  
goes out within 4 seconds, the system will make three  
ignition attempts. If the burner has not lit after the last  
ignition try, the gas valve will close and the system will  
go into lock out. DO NOT attempt to reset the system  
until the ignition system has been inspected and the  
problem resolved. Once the problem has been resolved  
and 5 minutes have passed since the last ignition attempt,  
reset the system by turning the thermostat to it's lowest  
setting and then back to where it was or by momentarily  
interrupting the electrical power to the boiler.  
electrical supply going to it. Make sure that gas is  
available at the gas valve inlet. Open the valves in  
the return and supply piping. Failure to take these  
precautions will prevent the boiler from operation  
properly.  
Fill the boiler and all of the radiation with water. Make  
sure that the system is completely purged of air.  
Review these instructions and make sure that the boiler  
installation complies with ALL of the instructions up to  
this point.  
BOILER OPERATION  
WARNING: Before operating read and  
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. Read and  
fully understand the operating instructions in  
the “For Your Safety Read Before Operating”  
section of this manual, pg 22 & 23. Failure to  
comply with this WARNING could result in a fire  
or explosion!  
D. With the burner in operation the manometer should  
show 1.9"W.C.manifold pressure. If not, see the BOILER  
CHECKING & ADJUSTMENT section.Close the manual  
shutoff valve in the gas supply line.As soon as the burner  
flame goes out, open the manual shutoff valve.A normal  
ignition sequence should take place.  
E. With the burner in operation, interrupt the power to  
the control circuit by lowering and raising the thermo-  
stat. A normal ignition sequence should follow.  
Should overheating occur or the gas supply fail to shut  
off, do not turn off or disconnect the electrical supply to  
the pump. Instead, shut off the gas supply at a location  
external to the appliance.  
F. To test the ignition safety shutoff device, close the  
manual shutoff valve in the gas supply line. Within 6  
seconds of main burner flame extinction, the main gas  
valve solenoid should close with an audible noise. The  
igniter should glow and make three attempts at ignition.  
After unsuccessfully attempting to light the burner the  
ignition module should lock out.  
En cas de surchauffe ou si l’alimentation de gaz ne peut  
être coupée, ne pas couper ni débrancher l’alimentation  
électrique de la ponpe. Fermer plutôt le robinet  
d’admission de gaz à l’extérieur de l’appareil..  
Open the manual shutoff valve in the gas supply line.  
Reset the ignition control system by interrupting, then  
restoring electrical power to the boiler. A normal ignition  
sequence should take place.  
Do not use this appliance if any part has been under  
water. Immediately call a qualified service technician to  
inspect the appliance and to replace any part of the  
control system and any gas control that has been under  
water.  
N’utiliisez pas cet appareil s’il a été plongé dans l’eau,  
même partiellement. Faites inspecter l’appareil par un  
tecnicien qualifié et remplacez toute partie du système  
de contrôle et toute commande qui ont été plongés dans  
l’eau.  
Direct Ignition System  
A. Connect a manometer to the pressure ports shown  
in Figure 20. Make sure that the gas supply piping has  
been purged of air and that all gas joints up to the gas  
valve have been thoroughly checked for leaks. Wait at  
least five minutes for any gas to dissipate before turning  
on the electrical power.  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Page 25  
Figure 20- Air and Manifold Pressure  
PROPANE GAS:  
The input rate for LP units is factory set based on the  
orifice size. The manifold pressure must be set at 1.9"  
W.C. and the orifice supplied with the boiler used unless  
the unit is to be derated for altitude.  
BOILER CHECKING & ADJUSTMENT  
INPUT RATE  
Gas appliances are rated based on sea level operation  
with no adjustment required at elevations up to 2000  
feet. At elevations above 2000 feet, input ratings should  
be reduced by 4% for each 1000 feet above sea level.  
Check the input rate as follows:  
CAUTION: Never increase the input to the boiler  
above that for which it is rated. Doing so can cause  
premature failure of the boiler!  
GAS PRESSURE ADJUSTMENT  
NATURAL GAS:  
1. Turn off all other gas appliances that use the same  
gas meter as the boiler.  
NATURAL GAS:  
Optimum results are obtained when the boiler is  
operated at its full input rating, with 1.9" W.C. of manifold  
pressure.The manifold pressure should not be more that  
5% off this value. The gas valve pressure regulator has  
been preset at the factory. If adjustment is necessary  
the following steps must be followed:  
2. Call the gas company for the gas heating value.  
3. Start the boiler and let it run for 15 minutes.  
4. Using the gas meter and a stopwatch, clock the time  
that it takes to burn 10 cubic feet of gas and divide  
the time by 10.  
5. Insert the heating value and the time, in seconds,  
into the formula below.  
1. Connect each side of a manometer to the two  
pressure ports shown in Figure 20 to obtain the  
manifold pressure.  
Input Rate = Heating Value(Btu/ft3)(3600 s/hr)  
Flow Rate(s/ft3)  
2. Connect a flue gas analyzer to the vent pipe.  
3. Rotate the regulator adjustment screw clockwise to  
increase the manifold pressure, counterclockwise to  
decrease it. Never force the regulator adjustment  
screw or the gas valve will be damaged!  
4. The CO2 reading should fall between 7% and 9%  
with a CO reading of less than 50 ppm air free.  
5. Adjust the air damper using the screw on the front  
of the filter box if the CO2 and CO readings are not  
within the range given in step 4.  
EXAMPLE: If the heating value = 1000 Btu/ft3  
and the flow rate = 36 s/ft3  
Input Rate = (1000 Btu/ft3)(3600 s/hr)  
36 s/ft3  
Input Rate = 100,000 Btu/hr  
6. Recheck the manifold pressure and adjust it if  
necessary.  
7. Replace the regulator adjustment screw cap and  
pressure port caps once the boiler is properly set  
up.  
If the computed rate deviates by more than 5% from the  
rated input value of the unit adjust the gas valve  
pressure accordingly. DO NOT adjust the manifold  
pressure by more than 5%. If a proper rate cannot be  
maintained without adjusting the manifold pressure  
beyond the 5% limit, the burner orifice must be replaced.  
If the input rate is too low go to the next larger size  
orifice. if the input rate is too high, go to the next smaller  
size orifice.  
PROPANE GAS:  
A manifold pressure of 1.9" W.C. must be maintained  
for proper operation of the boiler. If the manifold  
pressure is off by more than 5% or if the CO2 and CO  
readings are not within the range specified in step 4  
above, adjust it according to steps 1 through 7 above.  
Page 26  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Main Burner Flame  
A properly adjusted main burner flame will produce a  
Burner Box Removal & Replacement  
tight blue flame pattern about 1/2 inch tall from the  
burner’s surface, Figure 21. A yellow floating or tall  
stringy flame is not normal and must be corrected.  
CAUTION:The burner box should not be removed!  
Careless handling can damage the burner.  
WARNING:The ceramic combusiton chamber in  
the burner box and its gasket contain crystalline  
silica. Wear a tightly fitted dust mask when  
servicing the burner and gently handle the  
burner and its gasket to prevent inhalation of  
airborne fibers. Crystalline silica fibers have  
been identified as carcinogenic, or possibly  
carcinogenic when inhaled.  
WARNING:Yellow, floating flames indicate a lack  
of combustion air. DO NOT operate the boiler  
until the problem is solved or severe personal  
injury or death may occur!  
Figure 21 - Burner Flame  
If you suspect a problem within the burner assembly,  
please contact a local manufacturer representative.  
TIGHT BLUE FLAME  
Condensate System  
Ensure that the condensate removal system is sound  
and working properly.  
Vent System  
YELLOW FLOATING FLAME  
The entire vent system must be thoroughly inspected  
for any signs of blockage, corrosion or leaks.  
Immediately replace any unsound vent system piping.  
Remove any foreign matter in or near the vent terminal  
or around the boiler that might obstruct the flow of  
combustion and ventilation air.  
Thermostat Adjustment  
Set the heat anticipator to 1.1 amps when controlling  
the boiler directly. For zoned systems set the heat  
anticipator to match the amp draw of the zone valves  
or pump relays.  
Blower Motor  
Every 3 to 6 months, lubricate the inducer motor using  
2 drops of 20W non detergent motor oil in each oil port.  
BOILER MAINTENANCE  
The boiler should be cleaned and inspected once a  
year, before each heating season. Refer to Figures 22  
for component identification  
Low Water Cutoff  
If the boiler has been equipped with a low water cut-  
off device, follow the manufacturer's instructions for  
cleaning and to confirm proper operation  
CAUTION: Servicing, inspection and adjustment  
must be done by a trained technician in accordance  
with all applicable local and national codes.  
Improper servicing or adjustment could damage the  
boiler!  
Relief Valve  
The relief valve should vent water when the test lever  
is lifted. It should not weep or discharge water at normal  
system pressure. NEVER try to clean or repair the relief  
valve! If the valve fails replace it!  
Control Panel  
Use a soft brush and/or a vacuum cleaner to ensure that  
the electrical components are free from dust or deposits  
that would impair the boiler's performance.  
Aquastat High Limit  
The aquastat high limit controls the maximum water  
temperature in the boiler. It is adjustable from 140°F  
(60°C) to 220°F (104°C). If the water temperature  
reaches the set temperature before the demand for heat  
has been met, the aquastat high limit should shut the  
burners off. The outlet water temperature should never  
exceed 220°F (104°C). If the aquastat high limit fails to  
function properly replace it.  
Air Filter  
1. Remove the front jacket panel.  
2. Remove the filter box cover and filter.  
3. Wash the filter in warm water. Shake out all excess  
moisture before reinstalling.  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Page 27  
The symptoms of CO poisoning are often confused with  
INSTRUCTIONS TO THE INSTALLER  
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 INSTALLER must give this copy of the INSTAL-  
LATION AND OPERATING INSTRUCTIONS to the  
boiler owner and make sure that the owner or operator  
has a basic understanding of the following:  
1. The operating instructions, the type of ignition  
system installed and how it operates.  
2. What the labels on the boiler say.  
3. How to start up and shut off the boiler.  
4. How to turn the gas and electrical power on or off.  
5. What to do if the boiler ignition system locks out.  
6. Where to check the system temperature and  
pressure and what they should be.  
7. The importance of reading, understanding and  
following these instructions.  
8. The importance of visually inspecting the vent  
system on a monthly basis.  
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!  
The INSTALLER MUST make sure that the owner  
knows to shut the boiler off and call for service if the  
following conditions occur:  
1. Yellow lazy flames or flames outside the jacket.  
2. Gas smell or other strange odors.  
WARNING: Improper installation, adjustment,  
alteration, service or maintenance can cause  
property damage, personal injury exposure to  
hazardous materials or loss of life. Installation  
and service must be performed by a qualified  
installer, service agency or the gas supplier who  
must read and follow the supplied instructions  
before installing, servicing or removing this  
boiler. This boiler contains crystalline silica  
materials that have been identified as  
carcinogenic or possibly carcinogenic to  
humans when inhaled.  
3. Discoloration of the boiler or surrounding materials.  
4. Water leaking from the heating system piping or  
relief valve.  
5. Flue products leaking from the vent system into the  
living space. Dampness or condensation in the  
building is a good indicator of this condition.  
6. The boiler's flame rollout safety system is actuated.  
7. Control malfunction or sporadic operation.  
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.  
AVERTISSEMENT: Une installation, un réglage,  
une modification, une réparation ou un entretien  
non comforme aux normes peut entraîner des  
dommages matériels, des blessures exposition  
à des matières dangereuses ou la mort.  
L'installation et l'entretien doivent être effectués  
par un installateur ou un service d'entretien  
qualifié ou le fournisseur de gaz qui doivent  
avoir lu les instructions fournies avant de faire  
l'installation, l'entretien ou l'enlèvement de la  
chaudière et les respecter, Cette chaudière  
contient des matériaux qui ont été identifiés  
comme étant cancérogènes ou pouvant l' être.  
BRIEF EXPOSURE TO HIGH CONCENTRATIONS OF  
CO, OR PROLONGED EXPOSURE TO LESSER  
AMOUNTS OF CO MAY RESULT IN CARBON MON-  
OXIDE 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, vision problems, shortness of breath,  
headaches, loss of muscle control, unclear thinking,  
nausea, weakness and unconsciousness.  
Page 28  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Page 29  
SERVICE AND REPLACEMENT PARTS LIST  
Model Size with Item Quantities Below  
Ref #  
Name of Part  
Part #  
3
4
5
6
7
1
Rear, Top, Front & Inner Panels  
59450  
59451  
59452  
59453  
59454  
59495  
59496  
50064  
50065  
55532  
1
1
1
1
1
1
1
2
3
4
Left Jacket Side Panel  
1
1
1
1
1
1
1
1
1
1
1
Right Jacket Side Panel  
Gas Valve, White Rodgers 36E65  
Gas Valve, White Rodgers 36D27  
Blower, Fasco 702110816  
1
1
1
1
1
1
1
1
5
6
7
8
1
1
1
1
1
1
1
1
1
1
1
1
Transformer, Honeywell AT140B-1016, 40 VA 51032  
Ignition Control, UTC 1013-13B  
Pressure Switch  
51196  
.45 WC 55539  
.49 WC 55540  
.54 WC 55541  
60133  
1
1
2
1
1
1
1
9
Terminal Strip, 2 position  
Terminal Strip, 3 position  
Gas Tube  
2
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
2
1
1
1
1
10  
11  
12  
13  
14  
60134  
59396  
Filter  
50524  
Limit Control, Honeywell L6008A-1242  
Burner Box Assembly, NG Orifice  
includes items 15 thru 22 installed  
50524  
70-1050  
70-1051  
70-1052  
70-1053  
70-1054  
70-1055  
70-1056  
70-1057  
70-1058  
70-1059  
03-1006  
03-1007  
61023  
1
1
1
1
1
Burner Box Assembly, LP Orifice  
includes items 15 thru 22 installed  
1
1
1
1
1
1
1
1
1
15  
16  
17  
18  
19  
20  
RH Mounting Bracket  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
LH Mounting Bracket  
Barbed Fitting  
Male Connector 1/2"  
60861  
Compression Spring LC-045H-0  
Main Gas Orifice, Natural Gas  
0 - 2000' (consult factory for high altitude)  
20-1000  
59434  
59514  
1
59437  
1
1
59398  
1
59399  
1
Main Gas Orifice, LP  
59433  
1
0 - 2000' (consult factory for high altitude)  
59515  
1
59435  
59436  
1
59516  
1
1
1
1
1
1
1
3
1
4
21  
22  
23  
24  
O-Ring  
06-1002  
59499  
1
1
1
1
1
1
3
1
4
1
1
1
1
1
1
3
1
4
1
1
1
1
1
1
3
1
4
1
1
1
1
1
1
3
1
4
Blower Outlet Gasket  
Ground Rod PSE ME8  
Igniter, Norton 601XBM NG  
Igniter, Crystal Tech, LP  
Flame Sensor, PSE ME7  
Spring Clip  
50038  
50033  
16-1000  
50037  
25  
26  
27  
28  
59449  
Gasket  
59497  
1/4-20 x 2-1/4" Screw  
60824  
Page 30  
GS110 DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS  
Model Size with Item Quantities Below  
Ref #  
29  
30  
Name of Part  
Thermal Switch  
Block Assembly  
Part #  
59481  
72076  
72077  
72078  
72079  
72080  
59456  
59459  
59460  
59461  
59462  
59463  
59427  
59428  
59429  
59430  
59431  
59392  
03-1033  
03-1034  
03-1035  
03-1036  
03-1037  
59432  
72070  
72071  
61988  
60265  
76001  
76002  
76003  
76004  
76004  
76005  
76006  
3
1
1
4
1
5
1
6
1
7
1
1
1
6
1
1
6
1
6
31  
32  
Jacket Bracket  
6
1
6
1
Frame Cross Members  
1
1
33  
Flue Collector  
1
1
1
2
1
1
2
1
2
34  
35  
5/16-18 X 7-1/2" Stud  
Flue Collector Clamp  
2
1
2
1
1
1
1
1
1
1
1
1
1
36  
37  
Drain Filtting PEM CLS-0428-1  
Right Base Frame Assembly  
Left Base Frame Assembly  
Relief Valve  
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
38  
N/S  
N/S  
See  
Fig.  
20A  
Temperature & Pressure Gauge  
Transformer Primary Harness, P1  
Transformer Secondary Harness, P2  
Control Harness, P3  
1
1
1
1
1
1
1
1
Circulator Harness, P4  
HSI Harness, P6  
1
1
1
1
1
1
1
1
1
L1, L2 Harness, P7  
260 NORTH ELM STREET WESTFIELD, MA 01085  
TEL. (413) 562-9631 FAX: (413) 562-3799  

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