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USER’S INFORMATION MANUAL
S
ERIES
GM G
AS
B
OILERS
TO THE INSTALLER:
This manual is the property of the owner and must be affixed near the boiler for
future reference.
TO THE OWNER:
This boiler should be inspected annually by a Qualified Service Agency.
TO BE COMPLETED BY THE INSTALLER
Service Agency Phone No.
Address
Boiler Model No. GM- Serial No. Date of Installation:
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.
WWAARRNNIINNGG
– Do not store or use gasoline or other flammable vapors
and liquids in the vicinity of this or any other appliance.
– WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch;
do not use any phone in your building.
• Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire
department.
– Installation and service must be performed by a qualified
installer, service agency or the gas supplier.
GM8070 R3 (10/06-1M)
Printed in U.S.A.
PB HEAT, LLC
PO BOX 447 • NEW BERLINVILLE, PA 19545-0447
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Basic Operation
WARNING
CAUTION
Service on this boiler should be undertaken only by trained and skilled personnel from a
qualified service agency.
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.
Do not use this boiler if any part has been under water. Immediately call a qualified service
agency to inspect the boiler and to replace any part of the control system and any gas control
which has been under water.
A. General. This water boiler is a natural draft appliance and is equipped with controls for proper
operation. All controls must be in proper working order. Contact a qualified service agency to provide
annual maintenance as specified in Installation, Operation and Maintenance Manual.
1. Limit. See Figure 1. A Device which automatically interrupts boiler operation when the water
temperature exceeds the set point. Maximum temperature setting is 240°F (116°C).
Original equipment with this boiler is a Honeywell L4080. Boiler operation is interrupted when
system temperature reaches cut-out temperature. Boiler operation resumes automatically when
system temperature falls approximately 15°F (8°C) below the cut-out temperature.
2. Flame Rollout Switch. See Figure 1. A device which automatically interrupts boiler operation
when flames or excessive heat are present in the combustion area. The control is a single use
device. If the control is activated to interrupt boiler operation, do not attempt to place boiler in
operation. Contact a qualified service agency.
3. Vent Safety Shutoff Switch. See Figure 1. A device which automatically interrupts boiler
operation when there is a blockage in the vent pipe or chimney. The control is located on the draft
hood. The control is a manual reset device. If the control is activated to interrupt boiler operation,
do not attempt to place boiler in operation. Contact a qualified service agency.
4. Pilot. The pilot provides the ignition source for the main burners.
a. Intermittent Ignition or spark ignited pilot. Your boiler has an intermittent pilot. The pilot ignites
only when there is a call for heat and extinguishes when the call for heat ends. See Figures 1
and 5.
b. Standing Pilot. Your boiler has a continuous (standing) pilot. See Figures 1 and 6.
5. Gas Valve. The gas valve monitors pilot flame (boiler suffix “STDG” and “SV”) and regulates gas
flow to the main burners and pilot. See Figure 1.
6. Ignition Module (Boiler suffix “SPRK” only). The ignition module ignites the pilot and interrupt
boiler operation if it detects pilot flame failure.
7. Safety Relief Valve. A device which protects the boiler against excessive pressure. The safety
relief valve can discharge a large amount of hot water - the installer should provide piping to
discharge water near floor at a floor drain. If the safety relief valve discharges water, follow
instructions TO TURN OFF GAS TO APPLIANCE (see Figures 2 - 4), and contact a qualified
service agency.
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Figure 1: Control Locations
B. Operating Instructions: Instructions to place the boiler in operation and to turn off the boiler are
shown on the Lighting Instructions Label posted on the inside of the front jacket panel of the boiler.
The instructions are also shown in Figures 2, 3 and 4.
C. Sequence of Operation:
1. Thermostat calls for heat.
2. Limit senses boiler water temperature. Prevents operation until water temperature falls
approximately 15°F (8°C) below the cut-out temperature.
3. Automatic vent damper (if used) opens.
4. Gas valve energizes.
a. Intermittent Ignition
1. Igniter on.
2. Pilot gas on, igniting pilot.
b. Standing Pilot.
1. Gas valve energizes.
c. Spark Ignited Pilot.
1. Igniter Sensor Sparks.
2. Pilot gas on, igniting pilot.
5. Pilot flame detected.
a. Intermittent Ignition. Pilot flame detected.
1. Igniter off.
2. Main gas on, igniting main burners.
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Note 1: On SmartValve models (boiler suffix “SV”), if pilot flame is not detected within 30
seconds, the igniter is turned off for 30 seconds, and then turned back on. If the pilot is not
detected within 30 seconds, the igniter and pilot gas are turned off for 5 minutes. The
sequence then resumes at Step 4a.
Note 2: On Spark models (boiler suffix “SPRK”). If pilot flame is not detected within 90
seconds, the igniter and pilot gas are turned off for 5 minutes. The sequence then resumes at
Step 4a.
b. Standing Pilot. Pilot flame detected by thermocouple.
1. Main gas on, igniting main burners.
Note: If pilot flame is not detected, main and pilot gas are automatically turned off. Refer to
Paragraph B above to resume operation.
c. Spark Ignited Pilot. Pilot flame detected.
1. Main gas on, igniting main burners.
Note: If pilot flame is not detected withink 90 seconds, spark igniter and pilot gas are turned off
for five minutes. The sequence then resumes at Step 4.c.
6. Call for heat ends.
a. Intermittent Ignition/Spark Ignited Pilot
1. Pilot and main gas off, extinguishing pilot and main burners.
2. Automatic vent damper (if used) closes.
b. Standing Pilot.
1. Main gas off, extinguishing main burners.
2. Automatic vent damper closes.
If this sequence is not followed exactly, follow instructions TO TURN OFF GAS TO APPLIANCE (see
Figures 2 - 4), and contact a qualified service agency.
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Figure 2: Operating Instructions, SmartValve Intermittent Ignition (boiler model suffix “SV”)
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Figure 3: Operating Instructions, Spark Ignition (boiler model suffix “SPRK”)
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Figure 4: Lighting Instructions, Standing Pilot (boiler model suffix “STDG”)
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User Maintenance
WARNING
A. General Housekeeping (Continuous).
1. Keep boiler area clear and free of combustible materials and obstructions to the free flow of
combustion and ventilation air to the boiler.
2. Do not store or use gasoline or other flammable vapors or liquids in the vicinity of the boiler or any
other appliance.
3. Do not store or use sources of hydrocarbons in the vicinity of the boiler. Sources of hydrocarbons
include bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners and refrigerants.
4. Check safety relief valve for water leakage. If leakage exists, contact a qualified service agency.
B. Inspect Vent System (Monthly).
1. Vent pipe must be continuous to chimney with no separations, obstructions, or sags. Vent pipe
must be supported at minimum 4 foot (1.2 m) intervals and secured with sheet metal screws.
2. Chimney must not have signs of continuous wetness. If signs of continuous wetness are observed,
contact a qualified service agency.
C. Inspect Pilot and Main Burner Flames (Monthly).
1. Remove front jacket panel by lifting and pulling out.
2. Adjust thermostat to highest setting. Verify operation follows Sequence of Operation (see page 3.)
3. View flames through observation port. See Figure 1.
4. Check pilot flame. See Figures 5 and 6. The pilot flame should be medium blue covering
approximately 3/8" to 1/2" (10 mm to 13 mm) of the thermocouple or flame sensor. If the flame is
yellow and lazy, follow instructions TO TURN OFF GAS TO APPLIANCE (see Figures 2 - 4), and
contact a qualified service agency.
5. Check main burner flames. See Figures 5 and 6. The flames should have clearly defined inner
cones approximately 1-1/2" (40 mm) high and should have a very sharp blue color characteristic. If
the flame is yellow and lazy, follow instructions TO TURN OFF GAS TO APPLIANCE (see Figures
2 - 4), and contact a qualified service agency.
6. Adjust thermostats to normal setting.
7. Install front jacket panel.
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Service on this boiler should be undertaken only by trained and skilled personnel from a
qualified service agency. Inspections should be performed at intervals specified in the
Installation, Operation and Maintenance Manual and this User’s Information Manual. Maintain
manuals in a legible condition.
Keep boiler area clear and free of combustible materials, gasoline and other flammable vapors
and liquids.
Do not place any obstructions in boiler room that will hinder flow of combustion and
ventilation air.
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D. Controls (as required by control manufacturer)1.
1. Safety Relief Valve. Conduct try lever test as outlined in manufacturer’s instruction tag on the
safety relief valve.
2. Low Water Cut-off (if used). Follow instructions provided by control manufacturer.
E. General Inspection and Maintenance (Annual). For continued safe operation a qualified service
agency must provide a more detailed inspection of burners, heat exchanger and vent system, and
provide maintenance as specified in the Installation, Operation and Maintenance Manual.
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Figure 5: Intermittent Pilot and Main Burner Flames
1
Controls maintenance may be part of annual inspection and maintenance by a qualified service agency if annual frequency is
xspecified by controls manufacturer.
Figure 6: Standing Pilot and Main Burner Flames
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WARNING
Product Safety Information
Refractory Ceramic Fiber Product
This appliance contains materials made from refractory ceramic fibers (RCF). Airborne RCF,
when inhaled, have been classified by the International Agency for Research on Cancer (IARC),
as a possible carcinogen to humans. After the RCF materials have been exposed to
temperatures above 1800°F (980°C), they can change into crystalline silica, which has been
classified by the IARC as carcinogenic to humans. If particles become airborne during service
or repair, inhalation of these particles may be hazardous to your health.
Avoid Breathing Fiber Particulates and Dust
Suppliers of RCF recommend the following precautions be taken when handling these
materials:
Precautionar
y Measures:
Provide adequate ventilation.
Wear a NIOSH/MSHA approved respirator.
Wear long sleeved, loose fitting clothing and gloves to prevent skin contact.
Wear eye goggles.
Minimize airborne dust prior to handling and removal by water misting the material and avoiding
unnecessary disturbance of materials.
Wash work clothes separately from others. Rinse washer thoroughly after use.
Discard RCF materials by sealing in an airtight plastic bag.
Fir
st Aid Procedures:
Inhalation: If breathing difficulty or irritation occurs, move to a location with fresh clean air.
Seek immediate medical attention if symptoms persist.
Skin Contact: Wash affected area gently with a mild soap and warm water. Seek immediate
medical attention if irritation persists.
Eye Contact: Flush eyes with water for 15 minutes while holding eyelids apart. Do not rub eyes.
Seek immediate medical attention if irritation persists.
Ingestion: Drink 1 to 2 glasses of water. Do not induce vomiting. Seek immediate medical
attention.
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