Calumet GSA, GSA-075, GSA-100, GSA-200, GSA-250 User Manual

...

Download

Page 1

GSA

Gas-Fired Steam Boilers

Boiler Manual

Contents Page

1 Prepare boiler location ........................................................ 2

2 Prepare boiler ..................................................................... 6

3 Install piping ........................................................................ 9

4 Install controls .................................................................. 11

5 Install gas piping ............................................................... 12

6 Field wiring ....................................................................... 13

7 Start-up ............................................................................ 14

8 Checkout procedure ......................................................... 16

9 Sequence of operation ...................................................... 17

10 Lighting instructions .......................................................... 18

11 Service and maintenance ................................................. 20

12 Troubleshooting ................................................................ 24

13 Replacement parts ........................................................... 26

14 Dimensions ...................................................................... 30

15 Ratings ............................................................................. 31

Hazard definitions

Hazards that will cause severe personal injury, death or substantial property damage.

Hazards that can cause severe personal injury, death or substantial property damage.

INSTALLER — Read all instructions before installing. Read page 2 first. Follow all instructions in proper order to prevent personal injury or death.

• Consider piping and installation when determining boiler location.

• Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

• GSA boilers cannot be adapted for heater use.

This manual must only be used by a qualified heating installer/service technician. Failure to comply could result in severe personal injury, death or substantial property damage.

When calling or writing about the boiler— Please have: • boiler model number from the boiler rating label and • CP number from the boiler jacket. You may list the CP number in the space provided on the “Installation and service certificate” found on page 16.

Hazards that will or can cause minor personal injury or property damage.

Special instructions on installation, operation or maintenance that are important but not related to personal injury or property damage.

USER — Please read the following. Failure to comply could result in severe personal injury, death or substantial property damage.

• This manual is for use only by your qualified heating installer/service technician.

• Please see the User’s Information Manual for your reference.

• Have the boiler serviced by a qualified service technician, at least annually.

Part Number 550-110-738/0703

Page 2

GSA

Gas-Fired Steam Boilers – Boiler Manual

1 Prepare boiler locationRead this first!

Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage.

The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 32 of this manual. Failure to comply could result in severe personal injury.

When servicing boiler —

1. To avoid electric shock, disconnect electrical supply before performing maintenance.

2. To avoid severe burns, allow boiler to cool before performing maintenance.

Boiler operation —

3. Do not block flow of combustion or ventilation air to boiler.

4. Should overheating occur, turn off or disconnect electrical supply to boiler and shut off the gas supply at a location external to the appliance, if possible.

5. Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control that has been under water.

Boiler water —

6. DO NOT use petroleum-based cleaning or sealing compounds in boiler system. Water seal deterioration will occur, causing leakage between boiler sections, circulator flanges, diaphragm tanks or other system components. This can result in substantial property damage.

7. DO NOT use "homemade cures" or "boiler patent medicines". Serious damage to boiler, personnel and/or property may result.

8. Continual fresh makeup water will reduce boiler life. Mineral buildup in sections reduces heat transfer, overheats cast iron, and causes section failure. Addition of oxygen and other gases can cause internal corrosion. Leaks in boiler or piping must be repaired at once to prevent makeup water.

9. Do not add cold water to hot boiler. Thermal shock can cause sections to crack.

Codes & checklist

Installations must follow these codes:

• Local, state, provincial, and national codes, laws, regulations and ordinances.

• National Fuel Gas Code, ANSI Z223.1–latest edition.

• Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required.

• National Electrical Code.

• For Canada only: B149.1 or B149.2 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

Certification

The GSA boiler gas manifold and controls met safe lighting and other performance criteria when boiler underwent tests specified in ANSI Z21.13–latest edition.

Before locating the boiler:

❏ Check for nearby connection to:

• Venting connections

• Gas supply piping

• Electrical power

❏ Check area around boiler. Remove any combustible materials,

gasoline and other flammable liquids.

Failure to keep boiler area clear and free of combustible materials, gasoline and other flammable liquids and vapors can result in severe personal injury, death or substantial property damage.

❏ Boiler must be installed so that gas control system components

are protected from dripping or spraying water or rain during operation or service.

❏ If new boiler will replace existing boiler, check for and correct

system problems, such as:

1. System leaks causing oxygen corrosion or section cracks

from hard water deposits.

2 Part Number 550-110-738/0703

Page 3

GSA

1 Prepare boiler location continued

Clearances

Gas-Fired Steam Boilers – Boiler Manual

Service clearances

1. Provide minimum clearances for cleaning and servicing the boiler and for access to controls and components as listed in the table below.

2. Provide at least screwdriver clearance to jacket front panel screws for removal of front panel for inspection and minor service. If unable to provide at least screwdriver clearance, install unions and shutoff valves in system so boiler can be moved for servicing.

Service clearances: Minimum

Top

(for cleaning flueways)

Front

(for access to controls and components)

46"

18" Back 6" Left side

(for cleaning and servicing)

24" Right side 6"

Minimum clearance to combustible materials

General — all installations

1. Hot water pipes must be at least ½" from combustible material.

2. Single-wall vent pipe must be at least 6 inches from combustible material.

3. Type B double-wall metal vent pipe — See vent manufacturer’s recommendation for clearances to combustible material.

Small space — alcove (not closet) installation

GSA boilers are not approved for closet installation — only for alcove installation, with minimum

clearances as shown in Figure 1 and the table below, and the front side completely open — that is, a 3walled room.

Clearances from combustible materials: Minimum

Top 46" Front

(provide means of access)

Back 6" Left side

(provide means of access)

Right side 4"

Large space — (see minimum room volume, below)

If installed in a four-walled room, the room volume must be no less than the following (Ceiling height, if over 8 feet, can only be counted as 8 feet.):

GSA-075 & GSA-100 147 cubic feet GSA-125 & GSA-150 184 cubic feet GSA-175 & GSA-200 221 cubic feet GSA-250 257 cubic feet

The room must provide the following minimum clearances (in all directions) to the boiler and components:

Jacket and flue collector sides & rear 6 inches Jacket front 18 inches Vent pipe (other than Type B vent) 6 inches Vent damper 6 inches

Figure 1 Minimum clearances - alcove installation only

Residential garage installation

Take the following special precautions when installing the boiler in a residential garage. If the boiler is located in a residential garage, per ANSI Z223.1, paragraph 5.1.9:

• Mount the boiler a minimum of 18 inches above the floor of the garage to assure the burner and ignition devices will be no less than 18 inches above the floor.

• Locate or protect the boiler so it cannot be damaged by a moving vehicle.

Flooring and foundation

Do not install boiler on combustible flooring or carpeting even if a concrete or aerated foundation is used. Fire can result, causing severe personal injury, death or substantial property damage.

1. Provide a solid brick or minimum 2-inch thick concrete foundation pad if any of the following is true:

• floor can become flooded.

• the boiler mounting area is not level.

2. See Table 1 for minimum foundation dimensions.

3. Use a foundation with airways when:

• Electrical wiring or telephone cables buried in the concrete

floor of the boiler room.

• Concrete floor is “green”.

• Water is channeled under the concrete.

Table 1 Minimum foundation size

Boiler model

GSA-075 — GSA-100

GSA-125 — GSA-150

GSA-175 — GSA-200

GSA-250

Minimum

foundation

length

" 23

" 27

" 31

Minimum

foundation

width

19"

3Part Number 550-110-738/0703

Page 4

GSA

Gas-Fired Steam Boilers – Boiler Manual

1 Prepare boiler location continued

Vent system

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Inspect existing chimney before installing boiler. Failure to clean or replace perforated pipe or tile lining will cause severe personal injury or death.

Do not alter boiler draft diverter or place any obstruction or non-certified vent damper in breeching or vent system. CSA certification will become void. Flue gas spillage and carbon monoxide emissions will occur causing severe personal injury or death.

The following requirements apply when you remove an existing boiler from a vent system shared with other appliances. If the new boiler will not use the common vent, you must test (as described below) each remaining appliance — operating by itself — to verify that the vent system operates adequately.

When removing boiler from existing common vent system:

At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

a. Seal any unused openings in the common venting system. b. Visually inspect the venting system for proper size and horizontal

pitch and determine there is no blockage or restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.

c. Test vent system — 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 exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

d. Place in operation the appliance being inspected. Follow the

lighting instructions. Adjust thermostat so appliance will operate continuously.

e. Test for spillage at draft diverter relief opening after 5 minutes

of main burner operation. Use the flame of a match or candle.

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 conditions of use.

Any improper operation of common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1–latest edition. Correct by resizing to approach the minimum size as determined using the appropriate tables in Part 11 of that code. Canadian installations must comply with B149.1 or B149.2 Installation Code.

Equipment”, of National Fuel Gas Code, ANSI Z223.1–latest edition and applicable building codes. Canadian installations must comply with B149.1 or B149.2 Installation Codes.

2. See “Ratings” on page 31 for minimum chimney or vent sizes. Chimney or vent termination:

• A chimney, or any vent other than a Type B vent with listed

vent cap, must extend at least 3 feet above the highest point where it passes through a roof of a building, and at least 2 feet higher than any portion of a building within a horizontal distance of 10 feet.

• Type B vents with listed caps may terminate as in Figure 2

if no closer than 8 feet from a vertical wall or similar obstruction.

• Otherwise, Type B vents must terminate at least 2 feet above

the roof penetration and at least 2 feet higher than any portion of a building within 10 feet.

3. A lined chimney is preferred and must be used when required by local, state, provincial and national codes, laws, regulations and ordinances. Vitreous tile linings with joints that prevent retention of moisture and linings made of noncorrosive materials are best. Advice for flue connections and chimney linings can be obtained from local gas utility. Type B double-wall metal vent pipe or single-wall vent pipe may be used as a liner.

4. Cold masonry chimneys, also known as outside chimneys, typically have one or more walls exposed to outside air. When any atmospheric gas-fired boiler with automatic vent damper is vented through this type of chimney, the potential exists for condensation to occur. Condensation can damage a masonry chimney. The following are recommended to prevent possible damage.

a. Line chimney with corrosion-resistant metal liner such as

AL29-4C® single-wall stainless steel or B-vent. Size liner per National Fuel Gas Code ANSI Z223.1–latest edition.

b. Provide drain trap to remove any condensate.

5. Where two or more gas appliances vent into a common chimney or vent, equivalent area should be at least equal to area of vent outlet on largest appliance plus 50 percent of vent outlet area of additional appliances.

Figure 2 Terminations with Type B vent fitted with

listed cap, provided vent is at least 8 feet

from any vertical wall or similar obstruction

Chimney or vent requirements

1. Venting must be installed according to Part 7, “Venting of

4 Part Number 550-110-738/0703

Page 5

GSA

Gas-Fired Steam Boilers – Boiler Manual

1 Prepare boiler location continued

Air contamination Air openings

Please review the following information on potential combustion air contamination problems.

See Table 2 for products and areas which may cause contaminated combustion air.

To prevent potential of severe personal injury or death, check for products or areas listed below before installing boiler. If any of these contaminants are found:

• Remove contaminants permanently. — OR —

• Isolate boiler and provide outside combustion air. See

national, provincial or local codes for further information.

Table 2 Corrosive contaminants and likely locations

Products to avoid

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

Adhesives used to fasten building products and other similar products

Combustion air and ventilation openings must comply with Section

5.3, “Air for Combustion and Ventilation”, of National Fuel Gas Code ANSI Z223.1–latest edition, or applicable local building codes. Canadian installations must comply with B149.1 or B149.2 Installation Codes.

See table below for minimum combustion/ventilation air opening sizes. Where openings are required, provide two (2) openings — one within 12 inches of the ceiling, the other within 12 inches of the floor, as shown in the table illustrations.

Provide adequate combustion and ventilation air to assure proper combustion and reduce the risk of severe personal injury, death or substantial property damage caused by flue gas spillage and carbon monoxide emissions.

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

5Part Number 550-110-738/0703

Page 6

GSA

Gas-Fired Steam Boilers – Boiler Manual

1 Prepare boiler location continued

Air openings continued

Exhaust fans and air movers

The appliance space must never be under a negative pressure. Always provide air openings sized not only to the dimensions required for the firing rate of all appliances, but also to handle the air movement rate of the exhaust fans or air movers using air from the building or space.

2 Prepare boiler

Placement and setup

Place boiler/crate near position

1. Leave boiler in crate and on pallet until installation site is ready.

2. Move entire crate and pallet next to selected location.

3. Remove crate. Leave boiler on pallet.

4. Unbolt boiler from pallet.

5. Remove boiler from pallet.

Motorized air dampers

If the air openings are fitted with motorized dampers, electrically interlock the damper to:

• Prevent the boiler from firing if the damper is not fully open.

• Shut the boiler down should the damper close during boiler operation.

To accomplish this interlock, wire an damper open) in series with the thermostat input to the boiler. The boiler will not start if this damper is closed, and will shut down should damper close during operation.

Table 3 Manifold orifice sizing

isolated contact

(proving the

Inspect orifices and burners

1. Remove front jacket door. Remove base access panel (see Figure 16, item 14, page 26).

2. Check for correctly-sized manifold orifices. See Table 3 for sizing. (The orifice size is stamped on the orifice spud barrel.)

Correctly-sized manifold orifices must be used. Failure to do so will result in severe personal injury, death or substantial property damage.

3. Level and straighten burners.

Burners must be properly seated in slots in burner rest with their openings face up. Main burner orifices must inject down center of burner. Failure to properly seat burners will result in severe personal injury, death or substantial property damage.

4. Reinstall base access panel.

Do not operate boiler without access panel secured in place. Failure to comply could cause momentary flame rollout on ignition of main flame, resulting in possible fire or personal injury hazard.

Pressure test

Perform hydrostatic pressure test

Pressure test boiler before attaching water or gas piping or electrical supply.

Prepare boiler for test

1. Plug tappings or openings.

2. Do not use gauge supplied with boiler for pressure testing. Install gauge with appropriate range.

Fill and pressure test

1. Fill boiler with water. Vent all air. Test boilers between 45-50 psi.

Do not leave boiler unattended. A cold water fill could expand and cause excessive pressure resulting in severe personal injury, death or substantial property damage.

2. Check for maintained gauge pressure for more than 10 minutes. Visually check for leaks if gauge pressure drops.

6 Part Number 550-110-738/0703

Page 7

GSA

Gas-Fired Steam Boilers – Boiler Manual

2 Prepare boiler continued

Pressure test continued Draft diverter & spill switch

Drain and remove fittings

1. Drain boiler and repair leaks if found. Leaks must be repaired at once. Failure to do so can

damage boiler, resulting in substantial property damage.

Do not use petroleum based cleaning or sealing compounds in boiler system. Severe damage to boiler will result, causing substantial property damage.

2. Retest boiler after repairing leaks.

3. Remove plugs from any tappings that will be used for controls

and accessories. Refer to Table 4 and Figure 3, below.

Table 4 Control tapping

Figure 3 Control tapping locations

Draft diverter installation

1. Secure draft diverter to flue collector hood with sheet metal screws. See Figure 16, items 1 and 9, on page 26. Use boiler cement to provide gas tight seal.

Failure to maintain gas-tight seal can cause flue gas spillage and carbon monoxide emissions, resulting in severe personal injury or death.

Do not alter boiler draft diverter or place any obstruction or non-approved vent damper in breeching or vent system. CSA certification will become void. Flue gas spillage and carbon monoxide emissions will occur causing severe personal injury or death.

Spill switch installation

1. Fasten spill switch to draft diverter as shown in Figure 16, item 20, page 26.

2. See Wiring diagram on page 17 to connect wires.

Install vent piping

1. Connect from draft diverter or vent damper outlet to chimney or vent with same size vent connector.

2. Where possible, vertical venting to the outside from the draft diverter or vent damper outlet will offer best performance.

3. Where horizontal vent connector is used, slope upward at least ¼" per lineal foot toward chimney or vent and support with hangers to prevent sagging.

4. Breeching must not be connected to any portion of a mechanical draft system that can operate under positive pressure.

Long horizontal vent connector, excessive number of elbow or tees, or other obstructions that restrict the flow of combustion gases should be avoided. Severe personal injury, death or substantial property damage could result.

Float-type low water cutoff — If field installing a floattype low water cutoff, it must be piped only to the gauge glass tappings, items H, Figure 3. The tappings are spaced 9" on center. Use only float-type low water cutoffs with quick-connect hookups that will provide a low water cutoff point no higher than 2" above the center of the bottom tapping. See page 11, Figure 9, for a typical installation.

7Part Number 550-110-738/0703

Page 8

GSA

Gas-Fired Steam Boilers – Boiler Manual

2 Prepare boiler continued

Vent damper

These systems are used on gas-fired boilers with vent dampers as shipped from factory. Boiler will not operate without vent damper installed.

Damper blade

See vent manufacturer’s instructions to install plug (shipped with damper) in damper hole. Install plug with damper hole.

Minimum clearances

Provide a minimum of 6" between the vent damper and any combustible material. (See “Minimum clearance to combustible materials,” page 3, for minimum clearance from jacket top to ceiling to maintain this dimension.)

Damper installation

Do not modify draft diverter or vent damper, or make another connection between draft diverter and vent damper or boiler except as noted below. This will void CSA certification and will not be covered by warranty. Any changes will cause severe personal injury, death or substantial property damage.

1. Install vent damper as shown in vent damper manufacturer’s instructions. Vent damper must be installed so that it serves only one boiler and so damper blade indicator is visible to the user. See Figure 4.

2. Screws or rivets used to secure the vent damper to the draft diverter must not interfere with rotation of the damper blade.

3. Install damper harness between damper actuator and knockout in jacket top panel. Use strain relief connectors and locknuts to secure both ends of damper harness.

Keep wiring harness clear of all hot surfaces. Wire insulation could be damaged, causing risk of electrical short-circuit.

8" diameter hole in vent

4. Read and apply the harness plug warning label (shown above) so that it is visible after installation

5. Plug damper harness receptacle into damper harness plug.

Bypassing (jumpering) vent damper will cause flue products such as carbon monoxide to escape into the house. This will cause severe personal injury or death.

After boiler has operated once, if either end of harness is disconnected, the system safety shutdown will occur. The boiler will not operate until harness is reconnected.

Effikal damper — Damper hold open switch must be in Automatic Operation position for system to operate properly.

Figure 4 Vent damper assemblies

8 Part Number 550-110-738/0703

Page 9

3 Install piping

GSA

Gas-Fired Steam Boilers – Boiler Manual

General

1. Pipe before installing controls. Connect return piping after jacket is attached. Connect supply piping before or after jacket is attached.

Failure to properly pipe the boiler may result in improper operation and damage to the boiler or building.

2. See Figure 5 and Table 5. Pipe exactly as shown. Satisfactory operation of a steam heating system depends on adequate condensate return to boiler to maintain a steady water level. Avoid adding raw makeup water. Where condensate return is not adequate, install low water cutoff/pump control, condensate receiver and condensate boiler feed pump. Refer to Table 7, page 10, for sizing. See page 7, Table 4, for tapping locations.

Figure 5 Recommended piping, piping for parallel-

flow systems only.

Connecting to counterflow piping

Apply the recommended piping in Figures 4 through 7 only when connecting to a parallel-flow system. When connecting to a counterflow system, the boiler steam supply must connect into the top of the counterflow system header, as shown in Figure 6.

Figure 6 Connection to counterflow steam piping

Table 5 Recommended pipe sizing

Boiler model number Riser (A) Header (H)

GSA-075 and GSA-100 2" 2" 1½"

GSA-125 through GSA-175 2½" 2 ½" 1½"

GSA-200 and GSA-250 3" 3" 1½"

Note: 24" minimum from waterline to header.

see Note

Equalizer (J)

Relief valve

Install relief valve in tapping on top of boiler. See Table 4, page 7, for control tapping locations. See the tag attached to the relief valve for manufacturer’s instructions.

Follow the steps below to avoid potential severe personal injury, death or substantial property damage.

• When installing the relief valve, ensure that all connections, including the valve inlet, are clean and free from any foreign matter.

• Mount the relief valve only in the vertical position, directly connected to the tapping designated in the manual on top of the boiler.

• Use pipe compound sparingly, or tape, on external threads only.

• Do not use a pipe wrench! Use proper type and size wrench on wrench pads only.

9Part Number 550-110-738/0703

Page 10

GSA

Gas-Fired Steam Boilers – Boiler Manual

3 Install piping continued

Relief valve continued

During operation, this valve may discharge large amounts of steam and/or hot water. Therefore, to reduce the potential for bodily injury and property damage, a discharge line MUST be installed that:

• Is connected from the outlet to a safe point of discharge with no intervening valve.

• Allows complete drainage of both the valve and the discharge line.

• Is independently supported and securely anchored so as to avoid applied stress as possible.

• Terminates freely to atmosphere where any discharge will be clearly visible and is at no risk of freezing.

• Is, over its entire length, of a pipe size equal to or greater than that of the valve outlet. Use only schedule 40 metal pipe for discharge. (Do not use schedule 80, extra strong or double strong pipe or connections.) DO NOT CAP, PLUG OR OTHERWISE OBSTRUCT DISCHARGE PIPE OUTLET! If discharge is piped upward, a condensate drain must be provided in the elbow below the vertical pipe to prevent condensate from returning into the valve. Failure to comply with these instructions will cause a dangerous spray of hot water and steam that would cause severe personal injury or death.

Table 6 Reservoir pipe sizing

Boiler model number

GSA-075 75 GSA-100 100 GSA-125 125 GSA-150 150

GSA-175 175 1¾ GSA-200 200 2 GSA-250 250 2½

Designed full capacity steaming time of modern boilers is 10 minutes.

Boiler

gross

output

MBH

Time from initial steaming to average condensate

return (boiler steaming capacity based on 970 Btu per

15 minutes 20 minutes 30 minutes

gallons

1 1¼ 1½ 1½ 3 2½

pipe

length

(feet)

1 1

1¼

1¾

2¼

pound of steam)

gallons

pipe

length

(feet)

1½

2½

2¼

Use boiler feed system

gallons

pipe

length

(feet)

Use boiler feed

system

Condensate return

Modern steam boilers are designed to steam for less time than older, larger boilers. When replacing an older steam boiler the system condensate return time may be longer than the steaming time. This could cause the following problems:

1. Boilers fitted with an automatic water feed could overfill.

2. Units fitted with only a low water cutoff would shut down and cycle while waiting for condensate to return.

Following is a simple method for determining whether or not a reservoir pipe is required to lengthen steaming time for a residential installation:

1. Disconnect condensate return line at existing boiler.

2. Heat boiler and allow to steam for 10 minutes. Turn off boiler.

3. Measure length of time from when boiler started to steam to when condensate begins to return through condensate line.

4. Measure length of time from when condensate begins to return to when it stops returning. Divide this time by 2.

5. Add time measured in step 3 to time calculated in step 4. This sum is the average time required for condensate to return to the boiler.

6. If this total time is 10 minutes or less, no reservoir pipe is needed.

If total time for condensate to return to boiler (from step 5) is more than 10 minutes, a reservoir pipe (or boiler feed system) is recommended. See Table 6, this page, for suggested reservoir pipe size. Install as shown in Figure 7, below.

For larger systems (as noted in Table 6), use a boiler feed system with a condensate tank and feed pump. You will have to install a low water cutoff/pump control on the boiler to operate the pump. Use Table 7 to size boiler feed systems. See page 7, Table 4, for tapping locations. (The use of a combination condensate tank and floatcontrolled condensate return pump is not recommended.)

For most residential installations a reservoir pipe may be all that is necessary to ensure proper operation.

Figure 7 Recommended piping for parallel-flow

systems with optional reservoir pipe

Table 7 Boiler feed system sizing

Boiler model number

GSA-075 63 8 2 4 6 8 0.2

GSA-100 81 10 3 6 9 12 0.3

GSA-125 102 12 4 7 11 14 0.4

GSA-150 122 15 5 9 14 18 0.5

GSA-175 142 17 5 10 15 20 0.6

GSA-200 163 20 6 12 18 24 0.7

GSA-250 203 24 7 14 22 29 0.8

Notes

1. Maximum time to when condensate returns to boiler.

2. If pump capacity exceeds capacity shown, pump can be throttled with globe or ball valve.

I=B=R gross

output

(pounds

steam

per hour)

Conden-

sate

(gallons

per hour)

Minimum condensate receiver

capacity gallons for boiler

steaming times (minutes) of:

15 min. 30 min. 45 min. 60 min.

(note 1)

10 Part Number 550-110-738/0703

Suggested feed pump

capacity

(GPM @

15 PSI)

(note 2)

Page 11

4 Install controls

Controls

GSA

Gas-Fired Steam Boilers – Boiler Manual

Failure to properly install, pipe and wire boiler controls may result in severe damage to the boiler, building and personnel.

1. Controls are mounted and wired as shown in Figure 8. for actual tapping locations see Table 4 and Figure 3 on page 7.

2. Bring supply wiring to boiler. Must be 14 gauge or heavier.

3. See wiring diagram on page 17.

Figure 8 Controls

Float-type low water cutoff (when provided by others)

1. Install low water cutoff as shown in Figure 9, below. See Table 4 and Figure 3 on page 7 for actual tapping location.

2. Install blowdown line in bottom of cutoff. See control manufacturer’s instructions for details.

Pipe blowdown line near floor close to floor drain to eliminate potential of severe burns. Do not plug, valve or place any obstruction in blowdown line.

3. Water feeders are not recommended for primary control. A low water cutoff with pump controller is recommended with a condensate receiver and feed pump.

Figure 9 Float-type low water cutoff

(when provided by others)

11Part Number 550-110-738/0703

Page 12

GSA

Gas-Fired Steam Boilers – Boiler Manual

5 Install gas piping

Connecting gas supply piping to boiler

1. Remove jacket front panel and see Figure 10 to pipe gas to boiler.

a. Install drip leg at inlet of gas connection to boiler. Where

local utility requires drip leg to be extended to the floor, use

appropriate length of nipple between cap and tee. b. Install ground joint union for servicing, when required. c. Install manual shutoff valve in gas supply piping outside

boiler jacket when required by local codes or utility

requirements. d. In Canada — When using manual main shutoff valve, it must

be identified by the installer.

2. Support piping with hangers, not by boiler or its accessories.

3. Purge all air from gas supply piping.

4. Before placing boiler in operation, check boiler and its gas connection for leaks.

a. Close manual main shutoff valve during any pressure

testing at less than 13" w.c.

b. Disconnect boiler and gas valve from gas supply piping

during any pressure testing greater than 13" w.c.

Do not check for gas leaks with an open flame — Use bubble test. Failure to use bubble test or check for gas leaks can cause severe personal injury, death or substantial property damage.

5. Use pipe dope compatible with propane gases. Apply sparingly only to male threads of pipe joints so that pipe dope does not block gas flow.

Failure to apply pipe dope as described in this manual can result in severe personal injury, death or substantial property damage.

Natural Gas:

1. See Table 8 for pipe length and diameter. Base on rated boiler input, found on page 31 (divide by 1,000 to obtain cubic feet per hour). Table 8 is only for gas with specific gravity 0.60, with a pressure drop through the gas piping of 0.30" w.c. For additional gas pipe sizing information, see ANSI Z223.1 (B149.1 or B149.2 for Canadian installations).

2. Inlet pressure required at gas valve inlet:

• Maximum: 13" w.c.

• Minimum: 5" w.c.

• Manifold gas pressure: 3.5" w.c.

3. Install 100% lockup gas pressure regulator in supply line if inlet pressure exceeds 13" w.c. Adjust for 13" w.c. maximum.

Propane Gas:

1. Contact gas supplier to size pipes, tanks and 100% lockup gas pressure regulator.

2. Adjust propane supply regulator provided by gas supplier for 13" w.c. maximum pressure.

3. Inlet pressure required at gas valve inlet:

• Maximum: 13" w.c.

• Minimum: 11" w.c.

• Manifold gas pressure: 10" w.c.

Figure 10 Gas supply piping

Table 8 Pipe capacity for 0.60 specific gravity natural gas

Gas

pipe

length

(feet)

10 132 278 520 1050 1600 3050

20 92 190 350 730 1100 2100

30 73 152 285 590 860 1650

40 63 130 245 500 760 1450

50 56 115 215 440 670 1270

75 45 93 175 360 545 1020

100 38 79 150 305 460 870

150 31 64 120 250 380 710

½" ¾" 1" 1¼" 1½" 2"

Capacity of pipe for pipe size of:

Capacity in standard cubic feet gas per hour)

(

12 Part Number 550-110-738/0703

Page 13

6 Field wiring

GSA

Gas-Fired Steam Boilers – Boiler Manual

For your safety, turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death.

Wiring must be N.E.C. Class 1. If rollout thermal fuse element wire supplied with boiler

must be replaced, type 200 °C wire or equivalent must be used. If other original wiring supplied with boiler must be replaced, use only type 105 °C wire or equivalent.

Boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 70–latest edition.

Electrical installation must comply with:

1. National Electrical Code and any other national, state, provincial or local codes or regulations.

2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes.

Wiring connections

Boiler is shipped with controls completely wired, except spill switch and vent damper. See wiring diagram on page 17 for standing pilot ignition boiler.

Thermostat

1. Connect thermostat as shown on wiring diagram on boiler.

2. Install on inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, television, sunrays or fireplaces.

3. If thermostat has a heat anticipator, set heat anticipator in thermostat to match power requirements of equipment connected to it. If connected directly to boiler, set for 0.4 amps. For other devices, see manufacturer’s specifications. Wiring diagram on boiler gives setting for control module and gas valve. Also see instructions with thermostat.

Junction box

1. Connect 120 VAC power wiring (Figure 11). A separate electrical circuit with a fused disconnect switch (15 amp. recommended) should be used for the boiler.

Figure 11 Field wiring connections — service switch and thermostat (or end switch) provided by installer

13Part Number 550-110-738/0703

Page 14

GSA

Gas-Fired Steam Boilers – Boiler Manual

7 Start-up

Preparation

Check for gas leaks

Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Do not proceed with start-up if there is any indication of a gas leak. Repair any leak at once.

Propane boilers only — Your propane supplier mixes an odorant with the propane to make its presence detectable. In some instances, the odorant can fade and the gas may no longer have an odor.

• Propane gas can accumulate at floor level. Smell near the floor for the gas odorant or any unusual odor. If you suspect a leak, do not attempt to light the pilot.

• Use caution when attempting to light the propane pilot. This should be done by a qualified service technician, particularly if pilot outages are common.

• Periodically check the odorant level of your gas.

• Inspect boiler and system at least yearly to make sure all gas piping is leak-tight.

• Consult your propane supplier regarding installation of a gas leak detector. There are some products on the market intended for this purpose. Your supplier may be able to suggest an appropriate device.

Determine if water treatment is needed

Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to boiler will occur, resulting in substantial property damage.

Eliminate all system leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating cast iron, and causing section failure.

Consult local water treatment companies for unusually hard water areas (above 7 grains hardness) or low pH water conditions (below

7.0). Boiler water pH of 7.0 to 8.5 is recommended.

Fill the system with water

1. Do not fill (except for leakage tests) until boiler is ready to be fired.

2. Fill to normal waterline, halfway up gauge glass.

3. Boiler water pH 7.0 to 8.5 is recommended.

4. Follow skimming procedure, right.

Skimming the boiler

Clean all newly installed steam boilers to remove oil and grease. Failure to properly clean can result in violent fluctuations of water level, water passing into steam mains or high maintenance costs on strainers, traps and vents.

Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to boiler will occur, resulting in substantial property damage.

1. Provide 1½" piping from skim tapping to floor drain.

2. Adjust waterline to midpoint of skim tapping. See Figure 3, page 7.

3. Follow “Lighting Instructions” found on boiler or on pages 18 and 19 of this manual, to fire boiler to maintain temperature below steaming rate.

4. Feed in water to maintain water level. Cycle burners to prevent rise in steam pressure.

5. Continue skimming until discharge is clear. May take several hours.

6. Drain boiler. While boiler is warm, but not hot, flush all interior surfaces under full pressure until drain water runs clear.

7. Remove skim piping. Plug tapping.

8. Close drain cock. Fill with fresh water to waterline. Start burners and steam for 15 minutes to remove dissolved gases. Stop burners.

9. Check traps and air vents for proper operation.

10. Process may need to be repeated after several weeks of operation.

Inspect base insulation

Check to make sure insulation is secure against all four sides of the base. If insulation is damaged or displaced, do not operate boiler. Replace or reposition insulation.

Failure to replace damaged insulation or reposition insulation can result in a fire hazard, causing severe personal injury, death or substantial property damage.

14 Part Number 550-110-738/0703

Operate boiler

DO NOT proceed with boiler operation unless boiler and system have been filled with water and all instructions and procedures of previous manual sections have been completed. Failure to do so could result in severe personal injury, death or substantial property damage. Before starting the boiler . . .

• See pages 18 and 19, for “Lighting Instructions”.

• Verify the boiler and system water level is correct (no more than ½ of gauge glass or less than ¼" above bottom of gauge glass).

• Verify the “Preparation” procedures, on this page, have been completed.

Page 15

7 Start-up continued

GSA

Gas-Fired Steam Boilers – Boiler Manual

Operate boiler continued

Start the boiler

1. Check boiler water level — Should be approximately ½ way up gauge glass.

2. Remove boiler jacket door and note the gas valve manufacturer and model number.

3. Follow the “Lighting Instructions” on page 18 or 19, depending on gas valve installed in boiler. Use only the “Lighting Instruction” which applies to this gas valve. (The “Lighting Instruction” label on the boiler provides the same information.)

4. If boiler fails to start, see “If boiler doesn’t start . . . Check for:” on this page.

Check system and boiler

Eliminate all system leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating cast iron, and causing section failure.

If you discover evidence of any gas leak, shut down the boiler at once. Find the leak source with bubble test and repair immediately. Do not start boiler again until corrected. Failure to comply could result in severe personal injury, death or substantial property damage.

Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to boiler will occur, resulting in substantial property damage.

1. Check system piping for leaks. If found, shut down boiler and repair immediately.

2. Inspect vent system thoroughly for signs of deterioration from corrosion, physical damage or sagging. Verify that masonry chimney liners are in good condition, with no obstructions, and there are no openings into the chimney.

3. Check around the boiler for gas odor following the procedure of “Check for gas leaks”, page 14.

4. Verify operation using procedures below. Perform “Checkout procedure”, page 16, and fill in the “Installation and service certificate”.

If boiler doesn’t start . . . Check for:

1. Loose connections, blown fuse or service switch off?

2. High limit switch set below boiler pressure?

3. Thermostat set below room temperature?

4. Gas not turned on at meter or boiler?

5. Incoming gas pressure less than: 5" w.c. for natural gas? 11" w.c. for propane gas?

6. If none of the above corrects the problem, see “Troubleshooting”, page 24.

Verify operation

Check burner flame — Pilot burner

Proper pilot flame (see Figure 12):

1. Blue flame.

2. Inner cone engulfing thermocouple.

3. Thermocouple glowing cherry red.

Improper pilot flame:

1. Overfired — Large flame lifting or blowing past thermocouple.

2. Underfired — Small flame. Inner cone not engulfing thermocouple.

3. Lack of primary air — Yellow flame tip.

4. Incorrectly heated thermocouple.

Check burner flames — Main burner

Proper main burner flame (see Figure 13):

1. Yellow-orange streaks may appear (caused by dust).

Improper main burner flame:

1. Overfired — Large flames.

2. Underfired — Small flames.

3. Lack of primary air — Yellow tipping on flames (sooting will occur).

Figure 12

Typical pilot burner flame

Figure 13

Typical main burner flame

Check vent damper operation

1. Raise room thermostat to call for heat — Vent damper actuator will slowly open vent damper.

2. When vent damper is fully open — Main gas valve will open and main burners will ignite.

Vent damper must be fully open before main burners light. If vent damper does not fully open, flue products such as carbon monoxide will escape into house, causing severe personal injury or death.

3. Lower thermostat setting — Main burner flames will go out, then vent damper will close.

4. Repeat Steps 2 through 4 several times to verify operation.

5. Return thermostat to normal setting.

6. Set thermostat heat anticipator setting indicated on wiring diagram.

Check venting system operation

1. With boiler firing, hold a candle or match below lower edge of draft diverter “skirt.” If flame does not blow out, but burns undisturbed, the vent system is working properly. If flame blows out or flickers severely, the vent system must be checked for obstructions or other causes of improper venting.

15Part Number 550-110-738/0703

Page 16

GSA

Gas-Fired Steam Boilers – Boiler Manual

8 Checkout procedure

❏ Boiler filled with water?

❏ Boilers properly skimmed?

❏ Air purged from gas piping? Piping checked for leaks? ❏ Correctly-sized manifold orifices installed? See Table 3, page 6,

to check size and fuel type.

Correctly sized manifold orifices must be used. Failure to do so will cause severe personal injury, death or substantial property damage.

❏ Button on spill switch pushed in? ❏ Followed “Lighting Instructions” on boiler or in Manual Section

10, pages 18 and 19, for proper start-up?

❏ Proper burner flame observed? See “Verify operation”, page 15. ❏ Test limit control — While burners are operating, move indicator

on limit control below actual boiler pressure. Burners should go off. Raise setting on limit control above boiler pressure and burners should reignite.

❏ Test low water cutoff — Check probe-type low water cutoff for

proper operation. a. Turn off power to boiler and wait 5 minutes. b. Drain water to bottom of gauge glass. c. Turn on power. d. Set thermostat to call for heat. Red neon lamp on lower

water cutoff should light. e. Wait 5 minutes. Boiler should not fire. f. Refill boiler to correct water line. Red lamp should go off. g. Wait 5 minutes. Boiler should fire. h. Return thermostat to normal setting.

❏ Test additional field-installed controls — If boiler has an additional

high limit, low water cutoff or other controls, test for operation as outlined by manufacturer. Burners should be operating and should go off when controls are tested. When controls are restored, burners should reignite.

❏ Test ignition system safety device — Turn gas cock knob to

PILOT position and extinguish pilot flame. Pilot gas flow should stop in less than 3 minutes. Put system back into operation (see Section 7, pages 14-15).

❏ Set limit control(s) to system pressure requirements. Adjust

balancing valves and controls to provide design pressure to system.

❏ Verify thermostat heat anticipator (if available) set properly? See

“Thermostat”, page 13.

❏ Cycle boiler with thermostat — Raise to highest setting and

verify boiler goes through normal start-up cycle. Lower to lowest setting and verify boiler goes off.

❏ Measure natural gas input:

a. Operate boiler 10 minutes. b. Turn off other appliances. c. At natural gas meter, measure time (in seconds) required

to use one cubic foot of gas.

d. Calculate gas input:

3600 x 1000

number of seconds from step c

e. Btuh calculated should approximate input rating on boiler

rating label.

= Btuh

❏ Check manifold gas pressure by connecting manometer to

downstream test tapping on main gas valve. Manifold pressure for natural gas should be 3.5" w.c. and for propane gas should be 10" w.c.

❏ Observe several operating cycles for proper operation. ❏ Set room thermostat to desired room temperature. ❏ Fill in “Installation and service certificate” below? ❏ Review all instructions shipped with this boiler with owner or

maintenance person. Return instructions to envelope and give to owner or place in pocket inside front panel in boiler.

Installation and service certificate

Boiler model _______________________________________________________________ Series ____________

CP number _______________________________________ Date installed _________________________________

Measured Btuh input ____________

Installer _______________________ ______________________________ ____________________________

(company) (address) (phone)

16 Part Number 550-110-738/0703

 Installation instructions have been followed.

 Checkout sequence has been performed.

 Above information is certified to be correct.

 Information received and left with owner/maintenance person.

_____________________________________

(installer’s signature)

Page 17

GSA

Gas-Fired Steam Boilers – Boiler Manual

energizes the main gas valve. This provides gas to the main burners. Burners remain

ignited until thermostat circuit or limit circuit opens. Burners are deenergized when call

for heat stops.

the limit circuit closes again, the main gas valve is energized if there is still a call for

heat.

Figure 14.

3. Limit operation: When a limit control opens, the main gas valve is deenergized. When

4. Thermostat heat anticipator: Set heat anticipator as shown on wiring diagram,

Follow all procedures given in this manual and “Lighting Instructions” when

operating the boiler. Failure to do so could result in severe personal injury,

death or substantial property damage.

maintains pilot as long as the thermocouple is satisfied. If thermocouple signal drops

for any reason, pilot must be manually lighted, following the “Lighting Instructions” in

this manual and on boiler. Vent damper will remain closed until a call for heat.

The vent damper drives open. When the vent damper is fully open, its end switch

9 Sequence of operation

1. Standby mode: After pilot is manually lighted, the gas valve provides pilot gas and

2. Call for heat: When thermostat circuit closes, the boiler vent damper is energized.

Figure 14 Wiring diagram — Standing pilot system

17Part Number 550-110-738/0703

Page 18

GSA

Gas-Fired Steam Boilers – Boiler Manual

10 Lighting Instructions — GSA standing pilot boilers

Honeywell VR8200/VR8300 gas valve

FOR YOUR SAFETY READ BEFORE LIGHTING

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

A. This appliance has a pilot, which must be

lighted by hand. When lighting the pilot, follow these instructions exactly.

B. Before LIGHTING, 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. See below.

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

C. Use only your hand to push down the reset button or turn the gas control

knob. Never use tools. If the knob or reset button will not operate by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

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, which has been under water.

WHAT TO DO IF YOU SMELL GAS

LIGHTING INSTRUCTIONS

1. Stop! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. When equipped with Effikal vent damper Model RVGP, place service switch in Hold Damper Open position.

4. Turn off all electrical power to the appliance.

5. When equipped with Johnson Controls vent damper Model

M35, manually rotate damper blade in direction of arrow to Open position indicated on damper assembly.

6. Turn gas control knob clockwise

7. When equipped with vent damper, verify damper blade is in full open position.

8. 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. If you don't smell gas, go to the next step.

to OFF.

• 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.

9. Remove access panel located above burners.

10. Find pilot — follow metal tube from gas control. The pilot is between two burners behind the access panel.

11. Turn gas control knob counterclockwise PILOT.

12. Push in red reset button and hold. Immediately light the pilot with a match. Continue to hold reset button in for about one (1) minute after the pilot is lit.

13. Release reset button. Pilot should remain lit. If pilot goes out, repeat steps 6 through 13.

• If reset button stays depressed after release, stop and immediately call your service technician or gas supplier.

• If the pilot will not stay lit after several tries, turn the gas control knob clockwise or gas supplier.

14. Replace access panel.

15. Turn gas control knob counterclockwise

16. Turn on all electric power to the appliance.

17. When equipped with Effikal vent damper, place service switch in Automatic Operation position.

18. Set thermostat to desired setting.

19. Replace front panel.

to OFF and call your service technician

to ON.

TO TURN OFF GAS TO THE APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

18 Part Number 550-110-738/0703

3. Remove front panel.

4. Turn gas control knob clockwise

5. Replace front panel.

to OFF.

Page 19

GSA

Gas-Fired Steam Boilers – Boiler Manual

10 Lighting Instructions — GSA-30 through GSA-50

Robertshaw 7200 gas valve

FOR YOUR SAFETY READ BEFORE LIGHTING

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

A. This appliance has a pilot, which must be

lighted by hand. When lighting the pilot, follow these instructions exactly.

B. Before LIGHTING, 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. See below.

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

C. Use only your hand to push down the reset button or turn the gas control

knob. Never use tools. If the knob or reset button will not operate by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

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, which has been under water.

WHAT TO DO IF YOU SMELL GAS

LIGHTING INSTRUCTIONS

1. Stop! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. When equipped with Effikal vent damper Model RVGP, place service switch in Hold Damper Open position.

4. Turn off all electrical power to the appliance.

5. When equipped with Johnson Controls vent damper Model

M35, manually rotate damper blade in direction of arrow to Open position indicated on damper assembly.

6. Depress and move selector arm left

7. When equipped with vent damper, verify damper blade is in full open position.

to OFF.

• 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.

9. Remove access panel located above burners.

10. Find pilot — follow metal tube from gas control. The pilot is between two burners behind the access panel.

11. Move selector arm on gas control right to SET position.

12. Hold selector arm in SET position and immediately light the pilot with a match. Continue to hold selector arm to SET for about one-half (

13. Release selector arm. If pilot does not remain lit, repeat steps 6 through 13.

• If the pilot will not stay lit after several tries, move selector arm left supplier.

14. Replace access panel.

15. Turn selector arm left

16. Turn on all electric power to the appliance.

17. When equipped with Effikal vent damper, place service switch in Automatic Operation position.

18. Set thermostat to desired setting.

19. Replace front panel.

) minute after the pilot is lit.

to OFF and call your service technician or gas

to ON.

TO TURN OFF GAS TO THE APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Remove front panel.

4. Depress and move selector arm left

5. Replace front panel.

to OFF.

19Part Number 550-110-738/0703

Page 20

GSA

Gas-Fired Steam Boilers – Boiler Manual

11 Service and maintenance

Table 9 Service and maintenance schedules (service technician and owner)

Service technician

(see following pages for instructions)

❏

Inspect:

• Reported problems

• Boiler area

• Air openings

• Flue gas vent system

• Pilot and main burner flames

• Piping

• Boiler heating surfaces

• Burners and base

Service:

❏

START

• Gauge glass

Start-up:

❏

• Perform start-up per manual

NNNUAL

❏

Check/test:

Owner maintenance

(see User’s Information Manual for instructions)

❏ Daily • Check boiler area

• Check boiler pressure gauge

• Check air openings

❏ Monthly • Check boiler and system piping

• Check venting system

• Check/operate boiler relief valve

• Check pilot and main burner flames

❏ Periodically • Test low water cutoff

❏ End of season • Shut down procedure

• Gas piping

• Boiler waterline

• Limit controls and cutoffs

• Boiler relief valve

Review:

❏

• Review with owner

Follow the “Service and maintenance” procedures given throughout this manual and in component literature shipped with the boiler. See “Read this first!” on page 2. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death or substantial property damage.

20 Part Number 550-110-738/0703

Page 21

GSA

Gas-Fired Steam Boilers – Boiler Manual

11 Service and maintenance continued

The boiler should be inspected and started annually, at the beginning of the heating season, only by a qualified service technician. In addition, the maintenance and care of the boiler designated in Table 9, page 20 and explained on the following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could result in equipment failure.

Electrical shock hazard — Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death.

❏❏

❏ Inspect . . . . . . . . . .

❏❏

Reported problems

Inspect any problems reported by owner and correct before proceeding.

Boiler area

1. Verify that boiler area is free of any combustible materials, gasoline and other flammable vapors and liquids.

2. Verify that boiler area is free of any of the contaminants listed in Table 2 on page 5 of this manual. If any of these are present in the boiler intake air vicinity, they must be removed. If they cannot be removed, install combustion air piping to the boiler in accordance with national, provincial or local codes.

Air openings

1. Verify that combustion and ventilation air openings to the boiler room and/or building are open and unobstructed. Check operation and wiring of automatic combustion air dampers, if used.

2. Verify that boiler vent discharge and air intake are clean and free of obstructions.

Flue gas vent system

1. Visually inspect entire flue gas venting system for blockage, deterioration or leakage. Repair any joints that show signs of leakage in accordance with vent manufacturer’s instructions.

2. Verify that masonry chimneys are lined, lining is in good condition, and there are not openings into the chimney.

Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death.

Pilot and main burner flames

1. Visually inspect pilot burner and main burner flames as directed under Section 7, page 15 of this manual.

❏❏

❏ Inspect . . . . . . . . . .

❏❏

Piping

1. Check the boiler interior piping and all system piping for signs of leaks.

2. Repair any leaks before proceeding.

Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to boiler will occur, resulting in substantial property damage.

Eliminate all system or boiler leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating cast iron, and causing section failure. Leaking water may also cause severe property damage.

Boiler heating surfaces

1. Disconnect the vent pipe at the boiler draft diverter and remove draft diverter after turning off power to the boiler.

2. Use a bright light to inspect the boiler flue collector and heating surfaces.

3. If the vent pipe or boiler interior surfaces show evidence of soot, follow “Cleaning boiler heating surfaces”, page 23. Remove the flue collector and clean the boiler if necessary after closer inspection of boiler heating surfaces.

4. If there is evidence of rusty scale deposits on boiler surfaces, check the water piping and control system to make sure the boiler return water temperature is properly maintained (per this manual).

5. Reconnect vent and draft diverter. Replace all boiler components before returning to service.

6. Check inside and around boiler for evidence of any leaks from the boiler. If found, locate source of leaks and repair.

Burners and base

1. After turning off power to the boiler, remove the jacket door and base access panel (Figure 16, item 4, page 26).

2. Inspect burners and all other components in the boiler base.

3. If burners must be cleaned, raise rear of each burner to release from support slot, slide forward and remove. Then brush and vacuum the burners thoroughly, making sure all ports are free of debris. Carefully replace all burners, making sure burner with pilot bracket is replaced in its original position and all burners are upright (ports up).

4. Inspect the base insulation. a. Verify that the insulation is intact and secure against all

four sides of the base.

If insulation is damaged or displaced, do not operate the boiler. Replace or reposition insulation as necessary. Failure to replace damaged insulation can result in a fire hazard, causing severe personal injury, death or substantial property damage.

21Part Number 550-110-738/0703

Page 22

GSA

Gas-Fired Steam Boilers – Boiler Manual

11 Service and maintenance continued

❏❏

❏ Service. . . . . . . . . .

❏❏

Gauge glass

Normal waterline is halfway up gauge glass. Clean when needed.

1. Close lower gauge cock.

2. Open pet cock.

3. Open lower gauge cock and allow a small amount of water to flush out through open pet cock.

4. Close pet cock.

5. Open lower gauge cock.

Boiler pressure must be low to eliminate potential of severe burns.

If gauge glass breaks, close both gauge cocks. Replace gauge glass. Do not replace with thin glass tubing. Failure to comply could cause severe personal injury, death or substantial property damage.

❏❏

❏ Start-up. . . . . . . . . .

❏❏

1. Perform “Start-up” procedures, Section 7, pages 14-15, including “Verify operation” of burners and vent damper on page 15.

2. Check gas piping, per pages 12 and 14, verifying no indications of leakage and all piping and connections are in good condition.

3. Read the “Lighting Instructions” (page 18 or 19, whichever applies based on boiler gas valve).

4. Start the boiler following the “Lighting Instructions”, page 18 or 19.

❏❏

❏ Check/test. . . . . . . . . .

❏❏

Low water cutoffs

Probe-type low water cutoff (see below)

Clean probe-type low water cutoff for proper operation.

1. Turn off power to boiler and wait 5 minutes.

2. Drain water to bottom of gauge glass.

3. Turn on power.

4. Set thermostat to call for heat. Red neon lamp on lower water cutoff should light.

5. Wait 5 minutes. Boiler should not fire.

6. Refill boiler to correct waterline. Red lamp should go off.

7. Wait 5 minutes. Boiler should fire.

8. Return thermostat to normal setting.

❏❏

❏ Check/test. . . . . . . . . .

❏❏

Gas piping

1. Sniff near floor and around boiler area for any indication of a gas leak.

2. Test gas piping using bubble test, per page 12 of this manual, if there is any indication of a leak.

Boiler waterline

Normal waterline is halfway up gauge glass.

Limit controls

1. Inspect and test the boiler limit control. Verify operation by turning control set point below boiler pressure. Boiler should cycle off. Return dial to original setting.

Float-type low water cutoff (when provided by others — see below)

Clean float-type low water cutoff (when provided by others) to clear float chamber of sediment.

1. Open blowdown valve at bottom control.

2. Drain water into a bucket. Scald potential. Boiler pressure must be low to avoid

the potential of severe burns from steam.

3. Check float-type low water cutoff for proper operation:

a. Turn operating control to call for heat. b. Before water gets hot, drain to bottom of gauge glass. Boiler

should shut off after water level lowers a few inches.

c. Refill boiler to correct waterline. Boiler should come back

on.

22 Part Number 550-110-738/0703

Page 23

GSA

Gas-Fired Steam Boilers – Boiler Manual

11 Service and maintenance continued

❏❏

❏ Check/test. . . . . . . . . .

❏❏

Boiler relief valve

1. After following the warning directions below, if the relief valve weeps or will not seat properly, replace the relief valve.

Before testing, make certain discharge pipe is properly connected to valve outlet and arranged to contain and safely dispose of boiler discharge. Wear gloves to protect your hands from hot surfaces. Verify that discharge piping is installed in accordance with this manual and the instructions on the relief valve tag. Failure to comply will expose operator and others to severe personal injury or death.

Safety relief valves should be reinspected AT LEAST ONCE EVERY THREE YEARS, by a licensed plumbing contractor or authorized inspection agency, to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally. Certain naturally occurring conditions may corrode the valve or its components over time, rendering the valve inoperative. Such conditions are not detectable unless the valve and its components are physically removed and inspected. This inspection must only be conducted by a plumbing contractor or authorized inspection agency — not by the owner. Failure to reinspect the boiler relief valve as directed could result in unsafe pressure buildup, which can result in severe personal injury, death or substantial property damage.

Check the setting of the boiler limit control. The control should never be set with a pressure above 10 psig. Operating at a higher pressure can cause damage to the boiler relief valve.

The boiler relief valve must be tested at least monthly during the heating season to verify the valve and discharge piping flow freely. If corrosion and/or deposits are noticed within the valve body, testing must be performed more often. A “try lever test” must also be performed at the end of any non-service period. Follow the instructions below for a “try lever test”:

• With the system at operating pressure, lift and hold the test lever fully open for at least 5 seconds to flush the valve seat free of sediment and debris. Then release lever and permit the valve to snap shut.

❏❏

❏ Review with owner

❏❏

1. Review the User’s Information Manual with the owner.

2. Emphasize the need to perform the maintenance schedule specified in the User’s Information Manual (and in this manual as well).

3. Remind the owner of the need to call in a licensed contractor should the boiler or system exhibit any unusual behavior.

4. Remind the owner to follow the proper shutdown procedure and to schedule an annual start-up at the beginning of the next heating season.

❏❏

❏ Cleaning boiler heating surfaces

❏❏

1. Shut down boiler — Follow “To Turn Off Gas to Appliance” instructions on boiler and

2. Disconnect breeching and remove damper and draft diverter.

3. Remove upper rear jacket panel. Turn back jacket insulation to expose collector hood.

4. Remove collector hood. Clean excess boiler cement from collector hood and cast iron sections.

5. Remove burners from base of boiler. Follow “Burners and base” on page 21, to thoroughly clean burners. Place newspaper in base of boiler to collect soot that will fall.

6. With a wire flue brush, clean between the sections.

7. Remove paper and soot. Vacuum or brush base and surrounding area.

8. Replace collector hood. Seal with boiler cement.

“

Lighting Instructions”.

23Part Number 550-110-738/0703

Page 24

GSA

Gas-Fired Steam Boilers – Boiler Manual

12 Troubleshooting

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

Never jumper (bypass) rollout thermal fuse element or any other device except for momentary testing as outlined in “Chart 1”, page 25. Severe personal injury, death or substantial property damage can result.

Burner base access panel must be in position during boiler operation to prevent momentary flame rollout on ignition of main flame. Severe personal injury or substantial property damage will result.

Before troubleshooting:

1. Have the following items: a. Voltmeter that can check 120 VAC and 24 VAC. b. Continuity checker. c. U-tube manometer.

2. Check for 120 VAC (minimum 102 VAC to maximum 132 VAC) to boiler.

3. Make sure thermostat is calling for heat and contacts (including appropriate zone controls) are closed. Check for 24 VAC between thermostat wire nuts and ground.

In event of vent damper failure:

Effikal vent damper

If troubleshooting chart recommends replacing actuator and actuator is not immediately available, damper blade can be fixed in an open position to allow boiler operation. Manually turning blade can cause actuator damage. Follow these instructions only in case of no heat or damper actuator malfunction.

1. Move damper service switch to Hold Damper Open position. Apply call for heat to boiler. Damper blade should then rotate to Open position and boiler will fire.

2. If step 1 does not open damper, manually rotate damper blade to open position using wrench or pliers on flat shaft between damper and actuator. Boiler will fire. Verify that damper service switch is in Hold Damper Open position. See Figure 15.

3. Do not leave vent damper permanently in this position. Replace actuator immediately. If vent damper is left in Open position, boiler will not operate at published efficiencies.

Johnson Controls vent damper

If troubleshooting chart recommends replacing actuator and actuator is not immediately available, damper blade can be fixed in an open position to allow boiler operation. Follow these instructions only in case of no heat or damper actuator malfunction. See Figure 15.

1. Turn off power to boiler.

Failure to turn off power to boiler can result in severe personal injury, death or substantial property damage.

Troubleshooting sequence:

1. Before proceeding, check for:

• Loose connections, blown fuse or service switch off?

• High limit switch set below boiler water temperature?

• Thermostat set below room temperature?

• Gas not turned on at meter or boiler?

• Incoming gas pressure less than: 5" w.c. for natural gas? 11" w.c. for propane gas?

2. If all of the above check correctly, check gas pressures: a. With boiler off:

• 13" w.c. maximum natural or propane gas pressure upstream of gas valve.

b. With boiler on:

• 5" w.c. minimum natural gas pressure or 11" w.c. propane gas pressure upstream of gas valve.

• 3.5" w.c. minimum natural gas pressure or 10" w.c. propane gas pressure downstream tapping on gas valve — Can be adjusted by regulator on gas valve.

c. If gas pressure is incorrect or gas is not available to boiler,

contact gas supplier to correct before proceeding further.

3. Check pilot operation — Follow “Lighting Instructions”, pages 18 and 19.

• If gas is available and you cannot obtain a pilot flame, try

purging the gas line and cleaning pilot and pilot gas tubing. Follow “Lighting Instructions” again. If you still cannot obtain a flame, replace pilot burner and gas tubing. If this does not allow you to obtain a pilot flame, replace gas valve.

• If you obtain a pilot flame, but pilot will not remain on, replace

thermocouple. If this does not correct problem, replace gas valve and pilot burner.

• If pilot stays on, but main gas will not come on, proceed to

page 25.

2. See vent damper manufacturer’s instructions for procedure to fix vent damper in open position.

3. Turn on power to boiler.

4. Using wrench or pliers on flat shaft section, manually rotate damper blade until green light turns on. Boiler will fire. See Figure 15.

5. Do not leave vent damper permanently in this position. Replace actuator immediately. If vent damper is left in Open position, boiler will not operate at published efficiencies.

Figure 15 Manually opening vent damper

Verify proper operation after servicing. • See vent damper manufacturer’s instructions packed with vent damper for additional information. Failure to comply could result in severe personal injury, death or substantial property damage.

24 Part Number 550-110-738/0703

Page 25

GSA

12 Troubleshooting continued

Chart 1 — Standing pilot — Boiler will not fire

Before proceeding, follow "Troubleshooting sequence" on page 24. If problem persists, then:

Secure connections.

Gas-Fired Steam Boilers – Boiler Manual

Is damper harness securely plugged in at both ends?

No Yes

Check for loose wire connections or bad relay on transformer.

Check for open thermostat, LWCO, high limit, spill switch or rollout thermal fuse element contacts or check for loose wire connections.

If LWCO, spill switch or rollout thermal fuse element contacts are open, determine cause and correct condition. Failure to do so will cause severe personal injury, death or substantial property damage.

Check/repair out of round stack section. Does vent damper rotate open?

No Yes

Replace actuator. Retest.

Open thermostat contacts for 30 seconds. Vent damper will rotate to closed position. Close thermostat contacts. Vent damper will rotate to open position. Is 24VAC present across gas valve terminals?

No Yes

Is 24VAC present across transformer terminals C & Y?

No Yes

Is 24VAC present across transformer terminal C and yellow wire on vent damper connector?

No Yes

Is vent damper rotated open?

No Yes

Is 24VAC present across gas valve terminals?

No Yes

Is main flame on now?

No Yes

Retest

Is gas valve cock turned to ON position?

No Yes

Check continuity of each wire in damper harness. Does continuity exist for each wire? See Table right.

No Yes

Replace damper wiring harness. Retest.

Replace gas valve. Retest.

Remove damper harness from damper harness plug. TEMPORARILY install jumper between terminal 2 and terminal 5 on damper plug in boiler wiring harness. See Table, right. Does boiler fire?

No Yes

Replace damper actuator. Retest.

Turn gas valve cock to ON position. Retest.

Replace gas valve. Retest

25Part Number 550-110-738/0703

Page 26

GSA

Gas-Fired Steam Boilers – Boiler Manual

13 Replacement parts

Figure 16 Section assembly, flue collector, draft diverter, vent damper and base assembly

26 Part Number 550-110-738/0703

Page 27

13 Replacement parts continued

Figure 17 Jacket assembly

GSA

Gas-Fired Steam Boilers – Boiler Manual

27Part Number 550-110-738/0703

Page 28

GSA

Gas-Fired Steam Boilers – Boiler Manual

13 Replacement parts continued

Figure 18 Controls and trim

28 Part Number 550-110-738/0703

Page 29

13 Replacement parts continued

Figure 19 Gas controls

GSA

Gas-Fired Steam Boilers – Boiler Manual

29Part Number 550-110-738/0703

Page 30

GSA

Gas-Fired Steam Boilers – Boiler Manual

14 Dimensions

Figure 20 Dimensional drawing — ALL DIMENSIONS IN INCHES

Boiler model number

Supply

tapping

(inches NPT)

Return

tapping

(inches NPT)

GSA-075 3 2½

GSA-100 3 2½

GSA-125 3 2½

GSA-150 3 2½

GSA-175 3 2½

GSA-200 3 2½

GSA-250 3 2½

Note 2: Size gas piping from meter to boiler per local utility requirements.

30 Part Number 550-110-738/0703

Gas connection

& manifold size

(Note 2)

(inches NPT)

“V”

Damper

height

(inches)

“D”

Vent

diameter

(inches)

“W”

Jacket

width

(inches)

6 5 17 430

6 21¼ 505

9 7 25½ 585

8 29¾ 660

Approximate

shipping

weight

Page 31

15 Ratings

GSA

Gas-Fired Steam Boilers – Boiler Manual

DOE

Notes

1. Based on standard test procedures prescribed by the United States Department of Energy.

2. Net I=B=R ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup. Ratings are based on a piping and pickup allowance of 1.333. An additional allowance should be made for unusual piping and pickup loads.

3. See information at right for model number suffixes. Letters shown are model number suffixes. An “N” after the model number designates natural gas. An “L” designates propane gas.

4. Contact your local dealer regarding information and parts for high altitude applications.

31Part Number 550-110-738/0703

Page 32

GSA

Gas-Fired Steam Boilers – Boiler Manual

Handling ceramic fiber and fiberglass materials

REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS

The combustion chamber lining or base insulation panels in this product contain ceramic fiber materials. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, "Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).":

■ Avoid breathing dust and contact with skin and eyes.

• Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written. Other types of respirators may be needed depending on the job site conditions. Current NIOSH recommendations can be found on the NIOSH web site at

www.cdc.gov/niosh/homepage.html.

also listed on this web site.

• Wear long-sleeved, loose fitting clothing, gloves, and eye protection.

■ Apply enough water to the combustion chamber lining or base insulation to prevent airborne dust.

■ Remove combustion chamber lining or base insulation from the boiler and place it in a plastic bag for disposal.

■ Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.

NIOSH stated First Aid.

■ Eye: Irrigate immediately

■ Breathing: Fresh air.

NIOSH approved respirators, manufacturers, and phone numbers are

http://

REMOVAL OF FIBERGLASS WOOL — OR —

INSTALLATION OF FIBERGLASS WOOL, COMBUSTION CHAMBER LINING OR BASE PANELS:

This product contains fiberglass jacket insulation and ceramic fiber materials in combustion chamber lining or base panels in gas fired products. Airborne fibers from these materials have been listed by the State of California as a possible cause of cancer through inhalation.

■ Avoid breathing dust and contact with skin and eyes.

• Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements for fiberglass wool at the time this document was written. Other types of respirators may be needed depending on the job site conditions. Current NIOSH recommendations can be found on the NIOSH web site at

www.cdc.gov/niosh/homepage.html

also listed on this web site.

• Wear long-sleeved, loose fitting clothing, gloves, and eye protection.

■ Operations such as sawing, blowing, tear out, and spraying may generate airborne fiber concentration requiring additional protection.

■ Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.

NIOSH stated First Aid.

■ Eye: Irrigate immediately

■ Breathing: Fresh air.

. NIOSH approved respirators, manufacturers, and phone numbers are

http://

32 Part Number 550-110-738/0703

W-T

8201 W. Calumet Rd. Milwaukee, WI 53223