Slant/Fin Galaxy GG-75H, Galaxy GG-125H, Galaxy GG-150H, Galaxy GG-175H, Galaxy GG-200H Installation And Operating Instructions Manual

™

GAS-FIRED CAST IRON BOILERS FOR

NATURAL AND L.P. PROPANE GASES

GALAXY

HOT WATER BOILERS

INSTALLATION AND OPERATING INSTRUCTIONS

Models GG-75H through GG-399H and Models GXH-105 through GXH-190

CONTENTS .........................................................................PAGE

Dimensions..................................................................................2

Installation Requirements:

Boiler Location........................................ ................................3

Boiler Foundation....................................................................3

Chimney Requirements............................. .............................3

Minimum Clearance.....................................................................3

Vent Piping..............................................................................4

Gas Piping............................................. ......................................4

Boiler Room Air Supply and Ventilation......... .........................5

Draft Hood Installation.............................. ..............................5

Vent Damper Installation.........................................................6

Electrical Controls and Wiring.................... .................................8

Boiler Water Temperature Control.................... .........................11

Water Piping............................................. .................................13

Sequence of Operation of Galaxy Boilers .................................14

Care and Maintenance:

General Maintenance.................................. .........................15

Water Level Check................................................................17

Annual Inspection and Cleaning.......................... .................17

Safety Check for Control System..........................................17

Protection from Freezing, Water Treatment ..........................17

Keeping Area Clear ..............................................................17

Troubleshooting Guide...............................................................18

Piping a Heating and Cooling System.......................................19

Replacement Parts...................................... ..............................19

Appendix A ................................................................................19

READ ALL OF THE FOLLOWING WARNINGS AND

STATEMENTS BEFORE READING THE

INSTALLATION INSTRUCTIONS

Installation location ONLY as permitted in paragraph entitled
"LIQUEFIED PETROLEUM (L.P.) PROPANE GAS-FIRED
BOILER LOCATION" on page 3 of this instruction book.
The above warning does not apply to NATURAL gas-fired boilers.

The installation must conform to the requirements of the authori­ty having jurisdiction or, in the absence of such requirements, to
the National Fuel Gas Code, ANSI Z223.1-latest edition. The
installation must also conform to the additional requirements in
this Slant/Fin Instruction Book.

In addition, where required by the authority having jurisdiction,
the installation must conform to American Society of Mechanical
Engineers Safety Code for Controls and Safety Devices for
Automatically Fired Boilers, No. CSD-1.

This manual must be left with owner and should be hung on or
adjacent to the boiler for reference.

This boiler, gas piping and accessories must be installed, con­nected, serviced and repaired by a trained, experienced service
technician, familiar with all precautions required for gas-fired
equipment and licensed or otherwise qualified, in compliance
with the authority having jurisdiction.

IMPORTANT

WARNING

LIQUEFIED PETROLEUM (L.P.)

PROPANE GAS-FIRED BOILERS

WARNING

Heating Contractor

Address

Phone Number

Printed in U.S.A. 413 PUBLICATION GG-41 Rev. A

Part No. 41-0879

Boiler Model Number

Boiler Serial Number

Installation Date

2 GALAXY

ROLLOUT
SAFETY
SWITCH

T

RANSFORMER

120/24V

TEMPERATURE/
PRESSURE
GAUGE

GAS VALVE

I

GNITION

CONTROL

WATER
TEMPERATURE
CONTROL

G

AS

MANIFOLD

BURNERS

SUPPLY

VENT DAMPER

DRAFT HOOD

BLOCKED VENT

SAFETY SWITCH

PRESSURE
RELIEF
VALVE

RETURN

L

ocation and identification of parts

BOILER DIMENSIONS

FRONT VIEW

ll GG and GXH

A

RIGHT SIDE

G / GXH-PT

G

GG SERIES HOT WATER BOILERS - DIMENSIONS IN INCHES

GG-75H GG-100H GG-125H GG-150H GG-175H GG-200H GG-225H GG-250H GG-275H GG-300 GG-350H GG-375H GG-399H

A 19
B 131⁄4 131⁄4 131⁄4 161⁄2 161⁄2 20 20 231⁄4 231⁄4 263⁄4 30 30 30
C 566677 7 888910 10
D 46
E 63⁄4 13 15 13 13 16 16 17 17 17 221⁄2 15 22
F 8889
G 11⁄4 11⁄4 11⁄4 11⁄4 11⁄4 11⁄4 11⁄4 11⁄2 11⁄2 11⁄2 11⁄2 11⁄2 11⁄2
H 11⁄2 11⁄2 11⁄2 11⁄2 11⁄2 11⁄2 11⁄2 11⁄2 11⁄2 11⁄2 11⁄2 11⁄2 11⁄2
J 23⁄4 23⁄4 23⁄4 23⁄4 23⁄4 23⁄4 23⁄4 23⁄4 23⁄4 23⁄4 23⁄4 23⁄4 23⁄4
K 91⁄4 91⁄4 91⁄4 91⁄4 91⁄4 91⁄4 91⁄4 91⁄4 91⁄4 91⁄4 91⁄4 91⁄4 91⁄4

3

⁄4 193⁄4 193⁄4 23 23 261⁄2 261⁄2 293⁄4 293⁄4 331⁄4 361⁄2 361⁄2 361⁄2

3

⁄8 531⁄4 551⁄4 531⁄4 531⁄4 571⁄2 571⁄2 595⁄8 595⁄8 595⁄8 661⁄8 595⁄8 665⁄8

3

⁄4 93⁄4 111⁄4 111⁄4 13 13 143⁄4 161⁄4 161⁄4 161⁄4

GXH HOT WATER BOILERS - DIMENSIONS IN INCHES

A 23 23 261⁄2 261⁄2 261⁄2

ORIFICE SIZES indicated for Sea Level are factory installed in
boiler unless otherwise specified by the local authority.
See VII, page 12 for burner input adjustment.
GAS VALVE CONNECTION Size is 1/2" f.p.t. for all sizes up to and
including GG-300. Larger boilers, gas valves is 3/4".

COMBUSTIBLE FLOOR KIT increases all height dimensions by 1".
RAISED SLAB - When mounting boiler on a raised slab, the slab

must extend at least 2" beyond the boiler cabinet on all sides.
CHIMNEY HEIGHT: 15 ft. minimum from draft hood skirt to top of
chimney. CHIMNEY INSIDE DIAMETER must be same as Dimen-
sion “C” or larger. Larger diameter and/or height may be required if
two or more boilers or a boiler and another appliance are vented to
a single chimney.

B 161⁄2 161⁄2 20 20 20
C 5677 7
D 46
E 63⁄4 13 14 14 14
F 9
G 11⁄4 11⁄4 11⁄4 11⁄4 11⁄2
H 21⁄2 21⁄2 21⁄2 21⁄2 21⁄2
J 31⁄2 31⁄2 31⁄2 31⁄2 31⁄2
K 93⁄4 93⁄4 93⁄4 93⁄4 93⁄4

GXH-105 GXH-125 GXH-150 GXH-170 GXH-190

3

⁄8 531⁄4 551⁄2 551⁄2 551⁄2

3

⁄4 93⁄4 111⁄4 111⁄4 111⁄4

BOILER MODEL GAS TYPE 2,000

GG Natural 42 43 43 43 43 44 44 45 46 47

Except GG-399H

GG-399H

GXH-105 Natural 44 45 45 45 46 47 47 48 48 49
through 190 Propane 54 54 55 55 55 55 55 56 56 56

GG-350H

Propane 54 54 55 55 55 55 55 56 56 56

Natural 40 41 42 42 42 43 43 44 44 45

Propane 53 54 54 54 54 54 54 55 55 55

Natural

Gas* 43 44 44 44 45 45 46 47 47 48

*For L.P. Propane gas, consult factory.

Orifice

Size for

Sea Level

ORIFICE SIZES AT HIGH ALTITUDES

INCLUDES 4% INPUT REDUCTION FOR EACH 1000 FEET

3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000

ELEVATION–FEET

GALAXY 3

INSTALLATION REQUIREMENTS

The installation must conform to the requirements of the author­ity having jurisdiction or, in the absence of such requirements,
to the National Fuel Gas Code, ANSI Z223.1-latest edition.

This installation must also conform to the additional require-

ents in this Slant/Fin instruction book. Installation and service

m
to be performed by a qualified installer, service agency or the
gas supplier.

ATURAL GAS-FIRED BOILER LOCATION—

N

Provide a level, solid foundation for the boiler. Location should
be as near the chimney as possible so that the flue pipe from
boiler to chimney is short and direct.

Automatic gas ignition system components shall be installed so
these components will not be subjected to dripping water during
installation or service.

WARNING
LIQUEFIED PETROLEUM (L.P.) PROPANE GAS-FIRED
BOILER LOCATION

REQUIRES SPECIAL ATTENTION
Liquefied Petroleum (LP) propane gas is heavier than air.
Therefore, propane boilers, piping, valves should NOT be
installed in locations where propane leaking from defective
equipment and piping will "pool" in a basement or other
space below the leak.

A spark or flame from the boiler or other source may ignite
the accumulated propane gas causing an explosion or fire.
Provide a level, solid foundation for the boiler. Location
should be as near the chimney as possible so that the flue
pipe from boiler to chimney is short and direct.

THE UNIFORM MECHANICAL CODE may be in effect in
your geographic area.

The following precautions are cited by the 1994 UNIFORM
MECHANICAL CODE, section 304.6:

"LPG Appliances. Liquefied petroleum gas-burning
appliances shall not be installed in a pit, basement or
similar location where heavier-than-air gas might collect.
Appliances so fueled shall not be installed in an above­grade under-floor space or basement unless such loca­tion is provided with an approved means for removal of

unburned gas."
Consult Chapter 5 of the 1994 UNIFORM MECHANICAL
CODE for design criteria of the "approved" means for
removal of unburned gas.

BOILER FOUNDATION

A. Provide a solid, level foundation, capable of supporting the

weight of the boiler filled with water, and extending at least
2" past the jacket on all sides. See dimensions of boilers,
page 2.

B. For installation on non-combustible floors only.*

C. If boiler is to be located over buried conduit containing elec-

tric wires or telephone cables, consult local codes or the
National Board of Fire Underwriters for specific require­ments.

* The Combustible Floor Kit part number printed on the boiler rating plate is

the only one to be used when installing on combustible floors. The boiler
must NOT be installed on carpeting. DO NOT place boilers above floor
area containing radiant tubing.

CHIMNEY REQUIREMENTS—

. Galaxy boilers may be vented into a masonry vitreous tile-

A

lined chimney or UL LISTED Type “B” Venting system NOT
EXPOSED to the OUTDOORS below the roof line.
Venting and sizing of venting system must be in accordance

ith National Fuel Gas Code ANSI Z223.1, NFPA 54, -latest

w
edition which will be referred to as the National Fuel Gas
Code. Local codes apply.
If a masonry chimney is exposed to the outdoors on one or

ore sides below the roof line (exterior chimney), ONE of

m
the following options apply:

1. Chimney must be re-lined with a UL LISTED metallic liner.
When this is done, the chimney will be considered NOT
exposed to the outdoors and the requirements of the
National Fuel Gas Code for NON-exposed chimneys
and/or local codes will apply.

2. If an exposed tile-lined chimney is to be used WITHOUT a

UL LISTED metallic liner, the boiler must first meet the
requirements of the National Fuel Gas Code:

B. If an existing boiler is removed from a common venting sys-

tem, the common venting system may be too large for prop­er venting of the remaining appliances connected to the
common vent. Follow the test procedure shown in Appendix
"A" on page 19 of this manual to insure proper operation of
venting system and appliances.

C. Inspect for proper and tight construction. Any restrictions or

obstructions must be removed. An existing chimney may
require cleaning.

D. Chimney or vent must extend at least 3 feet above its pas-

sage through a roof and at least 2 feet above any ridge with­in 10 feet of the chimney.

MINIMUM CLEARANCES FROM COMBUSTIBLE CON­STRUCTION —

A. Minimum boiler clearances shall be as follows:

GALAXY GG SERIES

MODELS GG-75H
THROUGH GG-225H.
MINIMUM CLEARANCE
FOR COMBUSTIBLE
CONSTRUCTION.
MINIMUM CLOSET
CLEARANCE.
Front 6"
Rear 6"
Left Side 6"
Right Side 6"
Top 36"
Flue Connector 6"
Type 'B' Vent 1"

MODELS GG-250
THROUGH GG-399H.
MINIMUM CLEARANCE
FOR COMBUSTIBLE
CONSTRUCTION.
MINIMUM ALCOVE
CLEARANCE.
Front Alcove
Rear 6"
Left Side 6"
Right Side 6"
Top 36"
Flue Connector 6"
Type 'B' Vent 1"

4 GALAXY

GXH SERIES

MODELS GXH-105 THROUGH GXH-190
MINIMUM CLEARANCE FOR COMBUSTIBLE
CONSTRUCTION. MINIMUM CLOSET CLEARANCE.

ront 6"

F
Rear 6"
Left Side 6"
Right Side 18"
Top 36"
Flue Connector 6"
Type 'B' Vent 1"

B. Provide accessibility clearance of 24" on sides requiring ser-

vicing and 18" on sides used for passage.

C. All minimum clearances shown above must be met. This

may result in increased values of some minimum clearances
in order to maintain the minimum clearances of others.

D. Clearance from steam and hot water pipes shall be 1". **

** At points where hot water or steam pipes emerge from a floor, wall or ceil-

ing, the clearance at the opening through the finished floor boards or wall

r ceiling boards may be not less than 1/2". Each such opening shall be

o
covered with a plate of noncombustible material.

SAFETY—

KEEP THE BOILER AREA CLEAR AND FREE FROM
COMBUSTIBLE MATERIALS, GASOLINE AND OTHER
FLAMMABLE VAPORS AND LIQUIDS.

VENT PIPING—

A. Vent piping installation must be in accordance with ANSI

Z223.1-latest edition, National Fuel Gas Code, Part 7,
Venting of Equipment. Other local codes may also apply
and must be followed.

B. Boiler vent pipe must be the full diameter of the boiler draft

hood outlet. See dimensions, page 2. If a vent damper is
added, its diameter must be equal to the hood outlet and
must be located past the hood outlet. See installation
instructions furnished with vent damper and in the section
"Vent Damper Installation" of this instruction book.

C. If more than one appliance vents into a common breeching,

the area of the breeching must be equal to the area of the
largest vent plus 50% of the area of the additional vent
areas. Vent connectors serving appliances vented by natural
draft shall not be connected into any portion of mechanical
draft systems operating under positive pressure. Horizontal
breeching or vent pipe should be as high as possible, con­sistent with codes, so that vertical vents from appliances will
have a high rise above draft diverter openings. All horizontal
runs must slope upwards not less than 1/4 inch per foot of
run. Horizontal portions of the venting system must be sup­ported to prevent sagging by securing each joint with metal
screws and by providing hangers spaced no greater than 5
feet apart.

D. Vent or breeching into chimney should not be inserted past

the inside wall of the chimney liner.

E. All venting means should be inspected frequently. See Care

and Maintenance and separate User's Information Manual.

GAS PIPING—

. Local installation codes apply. The pipe joint compound used

A

on threads must be resistant to the action of liquefied petro­leum gases.

B. The gas supply line to the boiler should be run directly from

the meter for natural gas or from the fuel tank for L.P.
propane gas. See page 2 for location of union and manual

ain shut-off valve that may be specified locally.

m
Selecting pipe size for natural gas:

1. Measure or estimate the length of piping from the meter to
the installation site.

. Consult gas supplier for heating value of gas (BTU/cu. ft.).

2

3. Divide boiler rated input by heating value to find gas flow

in piping (cu. ft. per hour).

4. Use table below to select proper pipe size.

Example: Boiler model GG-300 is to be installed. Distance
from gas meter to the boiler is 50 ft. Heating value of natural
gas is 1020 BTU/cu. ft. Select proper pipe size.

Gas flow = 300,000 BTU/hour = 294 cu. ft. per hour

1020 BTU/cu. ft.

At 50 ft. length of pipe, match required capacity from table
below (choose higher capacity, in this case is 440 cu. ft. per
hour). Required pipe size is 1-1/4". Improper gas pipe sizing
will result in pilot flame outages, insufficient heat and other
installation difficulties. For more information and also if other
appliances are to be attached to the piping system, see
Appendix C of National Fuel Gas Code ANSI Z223.1-latest
edition.

C. The boiler and its gas connection must be leak tested before

placing the boiler in operation. Use liquid soap solution for
all gas leak testing. DO NOT use open flame.
This boiler and its individual shut-off valve must be discon­nected from the gas supply piping system during any pres­sure testing of that system at test pressures in excess of 1/2
PSIG.
This boiler must be isolated from the gas supply piping sys­tem by closing its individual manual shut-off valve during any
pressure testing of the gas supply piping system at test
pressures equal to or less than 1/2 PSIG.

D. All gas piping used should be inspected thoroughly for

cleanliness before makeup. A sediment trap must be provid­ed, as illustrated on page 2.

E. The minimum and maximum gas supply pressure (at the

inlet of gas valve) are shown on the boiler rating plate for the
type of gas used. Gas supply pressure should never be less
than minimum or more than maximum pressure when the
boiler or any other appliance is turned on or off.

Length
of Pipe
in Feet

Gas Flow In Piping — cu. ft. per hr.

Iron Pipe Size (IPS) — inches

1/2 3/4 1 1-1/4 1-1/2

10 132 278 520 1050 1600
20 92 190 350 730 1100
30 73 152 285 590 890
40 63 130 245 500 760
50 56 115 215 440 670
60 50 105 195 400 610
70 46 96 180 370 560
80 43 90 170 350 530
90 40 84 160 320 490

100 38 79 150 305 460

GALAXY 5

BOILER ROOM AIR SUPPLY AND VENTILATION

n ample supply of air is required to obtain combustion and

A
ventilation. Room temperature over 100°F may cause nuisance
tripping of the Blocked Vent Safety Switch.

ALL AIR MUST COME FROM OUTSIDE, directly through wall
openings to the boiler or through unsealed openings around
windows, doors, etc. in the whole building. When buildings are

nsulated, caulked and weather-stripped, now or later on, direct

i
opening to outside may be required and should be provided. If
the boiler is not on an outside wall, air may be ducted to it from
outside wall openings.

The National Fuel Gas Code, ANSI Z223.1-latest edition speci­fies openings for air under various conditions. Local codes may
specify minimum opening sizes and locations. The following
recommendation applies to buildings of energy-saving construc­tion, fully caulked and weather-stripped:

Provide one GRILLED opening near the floor and one near the
ceiling on an outside wall near the boiler (or duct from such
openings to the boiler), EACH opening to be a minimum of one
square inch per 2000 Btuh input to ALL APPLIANCES in the

area. For a total appliance input of 200,000 Btuh, each open-

ng will be 100 square inches. A grilled opening 10" x 10" has

i
100 square inches of area. If fly screen must be used over
openings, double the area and inspect and clean the screen
frequently.

Openings must NEVER be reduced or closed. If doors or win­dows are used for air supply, they must be locked open.

rotect against closure of openings by snow and debris.

P
Inspect frequently.

NO MECHANICAL DRAFT EXHAUST OR SUPPLY FANS ARE
TO BE USED IN OR NEAR THE BOILER AREA.

The flow of combustion and ventilating air to the boiler must
NOT be obstructed.

DRAFT HOOD—

The draft hood supplied is part of the listed boiler assembly.
DO NOT alter the hood. See dimensions, page 2.

Attach the hood to the boiler flue outlet. Connect flue pipe full
size of hood outlet. If a vent damper is added, it must be
installed on the outlet side of the hood. See Vent Piping,

6 GALAXY

VENT DAMPER INSTALLATION
The vent damper referred to in the following instructions
is the Slant/Fin Corporation vent damper.

This device is design certified by A.G.A. for use ONLY on spe-

ific Slant/Fin Corp. gas boiler models. These boilers must

c
also be equipped with a label which states that the boiler must
be used with a Slant/Fin Corp. automatic vent damper device
and indicates the proper vent damper model number.

. INSTALLATION INSTRUCTIONS BEFORE YOU START TO

A

INSTALL

1. Read this installation manual, the "DANGER" label
attached to the top of the boiler, the "WARNING" on the
wiring diagrams, vent damper carton and operator
cover.

Galaxy

Boiler

2. Perform pre-installation inspection as required by ANSI
specification Z21.66. (See Vent Damper Instructions.)

3. Select a proper, convenient location for vent damper.
Vent damper may be installed vertical or horizontal on
all models (see figures 1 and 2).

* Install operator in any position as shown above. DO NOT install the operator

bove the vent pipe (to avoid excessive heat) or below the vent pipe (to avoid

a
possible condensation damage).

4. Carefully unpack the unit. DO NOT FORCE IT OPEN OR
CLOSED! Forcing the damper may damage the gear

Figure 2. Horizontal or sloping installation of vent damper

train and void the warranty.

Figure 1. Vertical installation of vent damper on Galaxy Boilers

Figure 3.

GALAXY 7

WARNING—DANGER

Once you have begun vent damper installation procedure, DO
NOT restore electric power and gas supply until installation and
inspection have been completed (in order to prevent the main
burners from operating). DO NOT operate the boiler until the vent
damper harness is plugged into vent damper operator. Failure to
observe this warning may create a hazardous condition that could
cause an explosion or carbon monoxide poisoning.

. 1. This device must be installed after the boiler draft hood

B

(between the draft hood outlet and the connector to the
outdoor chimney or vent) as close to the draft hood as
practicable, and without modification of the draft hood or

he vent damper. (See figure 1 and 2.)

t

2. The inlet size of the vent damper must be the same nomi­nal trade size as the outlet of the draft hood.

3. This device must be located in a venting system or sec­tion of a venting system so that it serves only the single
appliance for which it is installed. (See figure 3.)

4. Clearances of not less than 6 inches (152MM) must be
maintained from combustible materials, with provisions for
service access.

C. AFTER INSTALLATION:

1. Operate system through two complete cycles to check for
opening and closing in proper sequence, and proper burner
operation. DAMPER MUST BE IN OPEN POSITION
WHEN BOILER MAIN BURNERS ARE

OPERATING.

2. Perform installation checks as required by ANSI specifi­cation Z21.66. (See Vent Damper Instructions.)

3. Check the troubleshooting section if problems arise with
the installation.

8 GALAXY

Z
T
TV

LO TEMP

HI TEMP

ECONOMY

24V

THERMOSTAT

H

YDROLEVEL HYDROSTAT CONTROL

M

ODEL 3200

HOT

NEUTRAL

120V/60Hz

CIRCULATOR

HONEYWELL IGNIT ION MODULE

GAS VALVE

L1

L2

C2

C1

B1

B2 I1

I2

24V(GND)

MV

MV/PV

PV

GND

(BURNER)

24V

GND

MV

PV

MV-PV

ROLL-OUT
SWITCH

PILOT GAS PIPE

IGNITOR CABLE

ELECTRIC

IGNITION

PILOT

: PROVIDE DISCONNECT MEANS AND
OVERLOAD PROTECTION AS REQUIRED
IF ANY OF THE ORIGINAL WIRE AS SUPPLIED
WITH THE APPLIANCE MUST BE REPLACED.
IT MUST BE REPLACED WITH TYP 105` OR

ITS EQUIVALENT.

VENT DAMPER

HARNESS

I

I

JUNCTION

BOX

SCHEMATIC WIRING DIAGRAM FOR GALAXY GG & GXH

BLOCKED VENT
SAFETY SWITCH

WIRE LEGEND:
FACTORY WIRED
FIELD WIRED, FIELD SUPPLIED

P

LUG

CAUTION:

LABEL ALL WIRE PRIOR TO DISCONNCTION WHEN SERVICING CONTROLS.
WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION.
"VERIFY PROPER OPERATION AFTER SERVICING".

RED

WHITE

BLK

BLUE

RED

RED

RED

B

L

A

C

K

W

H

I

T

E

WHITE

BLACK

GREEN

GREEN

ELECTRICAL WIRING

DANGER: Before wiring, always turn off electric power supply,

otherwise shock or death can result.

1. Power Supply

separately fused circuit is recommended. Use a standard

A
15 Amp. fuse or breaker and 14 gauge conductors in BX
cable or circuit.
Provide disconnect means and overload protection as
required. See boiler wiring diagram (Figure 4).
Boiler must be electrically grounded in accordance with
requirements of the authority having jurisdiction, or, in the
absence of such requirements, with the National Electrical

ode, ANSI/NFPA 70-latest edition.

C

2. Power Connection

Connect hot and neutral to black and white wires inside
junction box at the boiler (See figure 4).
Connect ground wire to ground screw inside junction box.

3. Thermostat Connections

Thermostat connections must be to T and TV screw
terminals of boiler temperature control (See Figure 4).

Thermostat Heat Anticipator Adjustments

If the 24v room thermostat that controls this boiler has an
adjustable heat anticipator, connect entire system to
thermostat and run the system while measuring the current

drawn through the thermostat wires. Set the heat
anticipator at the value measured. The set current should
match power requirements by zone valves and relays.
Add an additional 0.1 Amp to the measured currrent for vent
damper. Refer to the manufacturer’s instruction of zone
valve, vent damper and relays. Also, see instructions with

he thermostat.

t

4. Multi Zoning

For pump zoning system, see Figures 5 and 6, for zone
valve system, see Figure 7. DO NOT use control transformer
to power external accessories like zone valve and relays,
overload and/or burned-out transformer and boiler
malfunction can result.

. Indirect External Water Heater

5

If system includes indirect water heater, the indirect signal
must be separated from heating zones(s) system. See figure
6 and follow steps below:
a. Connect end switch of the indirect water heater relay

to I1 and !2 of the boiler temperature control.

b. Connect end switch of the heating zones(s) relays to

T and TV of the boiler temperature control.

c. Power DHW and heating zone(s) circulators through end

switch relays as sgown on figure 6. Do not connect
heating zone(s) circulators to C1 and C2 of the control.

Figure 4

GALAXY 9

Figure 5. Multizoning of Galaxy boilers pump zoning system using R845A relay.

Figure 6. Multizoning of Galaxy boiler-2 zone system pump zoning system using R882A/B relays.

10 GALAXY

Figure 7. Multizoning of Galaxy boilers zone valve system using V8043E/F zone valves.

GALAXY 11

Dynamic

Display

Water Temperature

and Real Time

Verification of

Setting Adjustments.

Low Temperature

Limit Setting

(OFF or 110°-200°F)

Factory OFF

H

igh Temperature
Limit Setting
(100°-220°F)

Factory 190°F

Diagnostic LEDs
a

nd Test Button

Jumper

Economy Dial
(OFF or LO, 1, 2, 3,
4, 5, HI)

Indicator Light
(announces heat

call)

Differentials are
automatic and will
vary based on
control settings and
boiler temperature.

BOILERS EQUIPPED WITH HYDROSTAT CONTROL

SETTING THE CONTROL

d

e

k

c

e

h

c

e

b

n

a

c

s

g

n

i

t

t

e

: S

E

T

O

N

.

n

o

t

t

u

B

S

G

N

I

T

T

E

S

/

T

S

E

T

e

h

t

g

n

i

s

u

T

I

M

I

L

GH

HI

HE

NG T

I

T

SET

t

a

t

e

s

y

r

o

t

c

a

f

is

it

lim

h

ig

h

e

h

T

I

H

e

th

rn

tu

t,

s

u

j

d

a

o

T

.

°F

0

9

1

d

e

ir

s

e

d

e

h

t

il

t

n

u

l A

Dia

P

EM

T

g

n

tti

e

(S

.

d

ye

a

l

p

s

i

d

s

i

g

n

tti

e

s

)

F

°

0

2

2

-

°

0

0

1

:

e

g

n

a

r

T

I

M

I

L

W

O

L

HE

NG T

I

T

SET

-

in

a

m

o

t

d

e

n

ig

s

e

d

is

it

lim

w

lo

e

h

T

s

s

le

k

n

a

t

h

wit

d

e

p

ip

u

q

e

s

r

ile

o

b

in

e

r

u

t

a

r

e

p

m

e

t

in

a

t

-

c

a

f

is

it

lim

w

lo

e

h

T

.

r

e

t

wa

t

o

h

ic

t

s

e

m

o

d

r

fo

d

e

s

u

ils

o

c

r

e

p

m

ju

e

h

t

ve

o

m

e

r

,

g

in

t

s

ju

d

a

o

t

r

io

Pr

F.

OF

o

t

t

e

s

y

r

o

t

P

EM

T

O

L

e

h

t

n

r

u

t

n

e

h

T

.

B

)

s

it

n

ll u

a

n

o

d

e

p

ip

u

q

e

t

o

n

(

-

is

is d

e

r

u

t

ra

e

p

m

e

t

d

e

sir

e

d

e

h

il t

t

n

u

kwise

c

clo

l C

Dia

it

lim

e

r

u

t

ra

e

p

m

e

low t

e

h

t

,

n

io

t

ra

e

p

o

r

e

p

o

r

p

r

o

F

.

d

e

y

la

p

-

t

se

it

lim

h

ig

h

e

h

low t

e

b

°

0

1

st

a

le

t

a

e

b

ld

u

o

sh

g

in

t

t

se

st

mu

it

low lim

e

h

t

,

n

io

t

ra

e

p

o

rt

a

st

ld

co

r

o

E: F

NOT

.

g

in

t

e

r

u

t

ra

e

p

m

e

t

it

low lim

f

: I

ANT

PORT

M

I

F.

OF

d

e

n

r

u

t

e

b

.

B

r

e

p

m

ju

ove

m

e

r

,

F

°

0

4

1

ove

b

a

t

se

e

b

t

o

n

n

ca

.

)

F

°

0

0

2

-

°

0

1

1

r

o

F

OF

:

e

g

n

ra

g

in

t

t

Se

(

I

T

SET

Eco

e

h

T

ju

d

a

To

d

e

y

la

p

wa

ct

e

r

r

u

t

a

Fe

m

r

e

h

T

p

p

su

o

t

n

r

u

t

e

b

ia

d

e

h

t

a

,

t

a

e

h

g

in

t

t

se

ls w

a

n

sig

r

u

t

a

Fe

e

t

a

u

q

This boiler is equipped with a feature that saves energy by reducing the boiler water
temperature as the heating load decreases. This feature is equipped with an over­ride which is provided primarily to permit the use of an external energy manage­ment system that serves the same function. THIS OVERRIDE MUST NOT BE
USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:

• An external energy management system is installed that reduces the boiler water
temperature as the heating load decreases.

•This boiler is not used for any space heating.

•This boiler has an input of 300,000 BTU/hr or greater

• This boiler is part of a modular or multiple boiler system having a total input of
300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.

NG T

n

,

st

q

e

r

e

t

co

e

l T

a

ly n

d

e

o

l t

d

d

xa

e

(

e

sh

e

m

e

t

o

u

h

a

e

t

2

r

p

HE

my

u

t

a

e

se

n

g

r

e

o

d

m

e

u

o

e

ECONOM

a

Fe

h

t

n

r

e

h

ls t

s in

r

e

t

a

s f

rve

g

in

t

e

h

d

e

d

e

low

a

1

r

o

savin

l

e

u

f

: 4

le

p

se

t

o

n

e

b

ld

e

r

u

t

ra

F

Y

o

ct

a

f

is

e

r

u

t

ECONOM

e

h

f

o

r

e

b

m

nu

m

nu

e

h

t

d

e

y r

l b

e

u

low)

e

rks” b

o

W

h

e

h

t

o

t

t

a

e

e

(

g

in

t

t

se

r

e

se

r

ve

n

Co

.

)

n

ca

s

g

h

t

f

I

.

)

5

r

o

wh

d

e

t

ra

a

p

OF

d

e

n

r

u

t

e

h

t

t

a

e

h

o

t

IMPORTANT NOTICE

EA

ry
Y

e

b

u

xa

ly,

b

e

e

F

e

cin

o

e

h

n
t

in

r

m
if

T

se

a

o

u

e

o

d

URE

Dia

in

t

f

g

I

.

se,

p

t

a

a

wir

in

ir

t

h
b

f

le

ch

t

e

t

g

h

in

su

fo
l

zo
e
o

h

t

:
e

ieve

in

ct

r

a
ile

e

h

I

b

g

g

r

n

zo

1

a

t

n

u

D

Do

s.

e

n

n

zo

g

in

t

p

m

e

t

r

g

in

t

a

e

h

ECONOM

e

e

e

r

h

t

a

n

p

r

ile

o

y

b

d

d

in

d

n

a

n

co

e

h

t

o

b

e

h

t

e

k.

n

a

t

e

il

n

e

ra

e

syst

zo

ovid

r

se

ir

r

t

ile

syst

g

in

t

a

e

h

b

m

nu

e

h

t

d

clu

in

t

o

Eco

e

h

T

s.

e

se

(

e

r

u

t

is u

m

e

l sh

Y Dia

se,

u

o

h

e

n

d

s a

e

a

g

in

ct

le

h

r

e

t

wa

ct

e

Eco

e

h

t

l,

o

lie

p

p

su

r

e

e

e

h

s

r

in

n

“

n

q

ig
e

n

m

e

is

d

d

my

o

How

ble

a

u

o

u

t

a

u

h

t

a

my

o

d

a

.

NOTE:

­with ta

-

i

ld

n

r

e

t

r

e

r

e

-

e

l Sma

Fue
max

oile

b

ll a

a

c
that is
If the
energ

ating

he
wirin

o Activ

T

sh

Pu

y

la

p

imize e

r temp

g is

will

nk

nd s

c

h

ize

a

eat is

n

Ac

le

upply

allin

the
y

s

need

ate

h

d

re

tiv

s

s
rt Hy

ffic
era

g. Durin

tems

s

o

d

a

ation of this

ils.

o

c

droStat h

nc

ie

tures

the late

ot s

n

burner

utiliz

ed.

Ther

e

h

t

ld

r

Pu

W

y.

o

d

the pu

g

ient to s

uffic

. Th

ing c

al Pr

m

TEST/

T

.

n

O

fea

a

en a

h

to 135° a

wn

t en

n

feature

is

irc

e-Pur

SETTI

e

d

o

tu

a

s

tiv

c

rgy

e

rge c

atis

ula

ct

a

ge

iva

not rec

re is

Therma

d, th

te

a

the

in

le

c

y

th

fy

k

wor

o

rs

to

S bu

NG

h

t

e

t

mmen

o

l Pre-Purg

trol will purg

n

o

e c

rt o

ta

t the s

boiler to the h

pla

dis

, the

rmos

e the

gle-

in

s

with

s

alves. No c

v

ne

r zo

r 2

o

f

n

o

t

t

,

re

u

t

a

e

f

e

f an

will indic

y
tat, th

e

s

0

u

p

THERMAL PRE-PURGE (OPTIONAL)

TING

A

ACTIV

button a second time for 20 seconds. The display will read Pur OFF.

SETTING

OFF Disables economy function. Will allow boiler to fire until hi

limit temp is reached and re-fire with a 10° subtractive
differential.

LO Provides lowest level of fuel savings. Use this setting only

if the house does not stay warm at higher settings.

1 Recommended setting for single zone systems
2 Recommended setting for Two zone systems
3 Recommended setting for Three zone systems
4 Recommended setting for Four zone systems
5 Recommended setting for Five zone systems

HI Provides highest level of fuel savings

de

and

co

sh

d fo

e fe

thermo

y

ting zo

ea

ontrol will

e c

multi-zon

s

d

n

d

n

a

oilers

r b

ature to

her

e hig

ta

s

n

Pur

ate

ge in

han

d

e

. Th

h

t

ld

o

h

t

e

.

e

-

is

e

12 GALAXY

SYSTEM START-UP HOW THERMAL TARGETING WORKS

At initial start up, with the Economy Feature active, the control
establishes a 145°F target temperature. To test the high limit
shut-off function, the Economy Dial must be turned to OFF.
Once tested, restore the Economy setting. If the heating
demand is high, the target will increase over time to satisfy the
heat load. NOTE: To reduce the potential for condensing, the
control will allow the boiler to heat to 120°F prior to energizing
the circulator.

LED LEGEND and TEST/SETTINGS BUTTON

u TEMP ACTIVE Indicates that the

Fuel Smart HydroStat control is pow­ered and that the temperature function
is active.

v TEMP HIGH TEMP Illuminates

when the boiler water temperature
reaches the high limit setting. It will
remain lit until the water temperature falls
10° (see High Limit Differential on page

4). The Fuel Smart HydroStat prevents
burner operation while this LED is on.

ACTIVE

❶❷❸❹❺❻❼

TEMP LWCO ECONOMY

ACTIVE

HI TEMP

w LWCO ACTIVE Indicates that the low water cut-off (LWCO)

function of the Fuel Smart HydroStat is active. When the
control is installed with a Hydrolevel Electro-Well, this LED will be
on at all times when the control is powered.
IMPORTANT: If the control is installed with a well other than the
Electro-Well, this LED will not illuminate indicating that the control
is not providing low water cut-off functionality.

Thermal Targeting technology analyzes thermostat activity and
continually evaluate how much heat the house requires. When
it is very cold outside, the heat demand is high and the Fuel
Smart HydroStat will raise the boilers Target temperature to
provide needed heat to the home. When the outside tempera­ture is milder, the heat demand is lower. During these periods,
the Fuel Smart HydroStat will lower the boilers Target temper­ature – saving fuel – while continuing to provide comfort to the
house.

boiler water reaches the target tempera­ture, the LED illuminates and the burner
will shut down. The boiler water will con­tinue to circulate and heat the house as
long as the thermostat call continues.
The LED will stay lit until the boiler tem­perature drops to the differential set point

LOW WATER

ACTIVE

TARGET

TARGET SETTINGS

(see Target Temp Differential on page 4)
at which point the boiler will be allowed to
fire again. NOTE: This LED illuminates
regularly during normal boiler operation.

❼ TEST/SETTINGS Button

To Test Low Water Cut-Off: Press and hold the Test/Settings but­ton for 5 seconds. The display will read LCO.

LWCO TEST LCO

The red Low Water light should illuminate and the burner circuit
(B1 and B2) should de-energize. NOTE: The control must be
installed with a Hydrolevel Electro-Well for low water cut-off func­tionality (see page 2 for more details).

❹ LWCO LOW WATER Illuminates if the boiler is in a low water

condition. The Fuel Smart HydroStat will prevent burner operation
during this condition. IMPORTANT: The system must be checked

by a qualified heating professional prior to resuming operation.

WARNING: DO NOT ADD WATER UNTIL THE BOILER
HAS FULLY COOLED.

❺ ECONOMY ACTIVE Indicates that the Thermal Targeting

function is active and the Fuel Smart HydroStat will reduce boiler
temperature to conserve fuel. The Economy feature is activated
using the ECONOMY dial. (See “How Thermal Targeting Works”
on page 4 for more information).

➏ ECONOMY TARGET When the Economy feature is active,

the Fuel Smart HydroStat continually sets target temperatures
below the high limit setting to maximize fuel efficiency. When the

To View Current Settings: Press and release the Test/Settings Button
in short intervals to sequentially display the following settings:

HIGH LIMIT SETTING HL

q

LOW LIMIT SETTING LL

q

ECONOMY SETTING ECO

q

CURRENT TARGET TEMPERATURE ooo

q

PRE-PURGE SETTING Pur

The display will return to boiler temperature (default) if

Test/Settings Button in not pressed for 5 seconds.

GALAXY 13

WATER PIPING

I. CIRCULATING SYSTEMS

. Packaged water boilers are equipped with a water cir-

A

culating pump, mounted to return the water into the
boiler. For some installations, the pump should be on
the supply main. See figure 8.

II. AIR CONTROL SYSTEM

A. DIAPHRAGM-TYPE COMPRESSION TANKS are used

to control system pressure in an AIR ELIMINATING
SYSTEM: an automatic air vent is used to REMOVE air
from the system water. See figure 8. If system pressure
needs further control, add an additional tank or install a
larger capacity tank. Locate the tank near the boiler, as
illustrated.An automatic air vent should be installed in
the top of the boiler or air purger. See figure 8.

B. PUMP LOCATION — Locating low-head pump(s) on

return to boiler is acceptable for smaller boiler sizes in
residences of one or two stories. The alternate pump
location shown in illustration is required in large, multi­story building installations, especially when high-head
pumps are used. The compression tank must be at the
boiler or between boiler and supply main pump(s).
IMPORTANT

: Hot water heating systems containing
high water volume, such as would occur with cast-iron
radiation, require special care with air elimination.
The circulator pump should be located on the boiler
supply pipe and the expansion tank and air scoop
should be located near the pump suction.

OPERATING INSTRUCTIONS

FILLING AND VENTING WATER SYSTEMS

A. Fill the system with water. Vent or purge off air.
B. Fire the boiler as soon as possible (see following warning

and instructions) and bring water temperature to at least
180 degrees, while circulating water in the system.

C. Vent air and add water as needed to achieve operating

pressure on boiler gauge. Pressure must be between
approximately 12 psi (cold water) and 25 psi (at water
temperature setting of high limit control), for boilers
equipped with 30 psi relief valves. Boilers rated for a high­er pressure and equipped with a matching relief valve may
operate at a higher pressure, but no higher than 5 psi
below the relief valve opening pressure.

D. Check for and repair any leaks before placing system in ser-

vice.
Before firing boiler, make these checks:

1. System is full of water. Air is vented or purged.

2. Relief valve is installed in accordance with the ASME
Boiler Pressure Vessel Code, Section IV. Valve opening is
not closed or reduced in size.

3. Venting is installed according to instructions under “VENT
PIPING”.

4. All wiring is completed, following applicable wiring dia­grams.

5. Using soap solution, check for gas leaks in all gas piping
from meter to boiler pilot and manifold. DO NOT use open
flame.

Figure 8. Piping arrangement

14 GALAXY

SEQUENCE OF OPERATION FOR GALAXY BOILERS

L

OW LIMIT (FOR BOILERS WITH

T

ANKLESS COIL) CALLS

FOR HOT WATER

N

NONO

O

O FURTHER

N

NATURAL GAS (S8600F)

IGNITION SPARK CON-

TINUES. PILOT VALVE

REMAINS OPEN UNTIL

SYSTEM IS RESET.

CTION

A

IRCULATOR IS OFF UNTIL

C

OILER WATER TEMPERATURE

B

REACHES 120˚F

L

.P. PROPANE GAS

(S8600M AND S8670E)

IGNITION TRIAL CONTIN-

UES FOR 90 SECONDS.

AFTER TRIAL FOR IGNI-

T

ION, SYSTEM SHUTS OFF.
A

FTER 5 MINUTES MOD-

ULE RE-INSTATES TRIAL

FOR IGNITION. IF PILOT

FLAME NOT ESTABLISHED,

IGNITION TRIAL, SYSTEM

SHUT-OFF AND 5 MINUTES

WAIT SEQUENCE REPEATS

CONTINUOUSLY.

THERMOSTAT CALLS

F

OR HEAT

IGH-LIMIT CONTACTS CLOSED?

H

ENT DAMPER RELAY ENERGIZED.

V

ENT DAMPER MOTOR MOVES OPEN VENT DAMPER.

V

S

S8600F OR S8600M: IGNITION SPARK STARTS AND PILOT VALVE OPERATOR OPENS.

S8670E: IGNITION SPARK AND PILOT VALVE OPERATOR DELAYED FOR 30-70 SECONDS.

SPARK GENERATOR OFF. MAIN VALVE OPERATOR OPENS. MODULE MONITORS PILOT FLAME.

END SWITCH CLOSES.

IGNITION CONTROL ENERGIZED

PARK GENERATOR MODULE POWERED

THE PILOT FLAME ESTABLISHED?

OR

YES

YES

WHEN THERMOSTAT IS SATISFIED OR WHEN HIGH LIMIT, LOW LIMIT, OR LOW WATER CUT-OFF CONTACTS ARE OPEN,

VALVE OPERATORS CLOSE, VENT DAMPER CLOSES. CIRCULATOR OFF. SYSTEM GOES TO STANDBY.

GALAXY 15

SAFETY INFORMATION

FOR YOUR SAFETY READ BEFORE OPERATING

ARNING: If you do not follow these instructions exactly,

W
a fire or explosion may result causing property damage,
personal injury or loss of life.

. This appliance is equipped with an ignition device which

A

automatically lights the pilot. DO NOT try to light the pilot
by hand.

B. BEFORE OPERATING smell all around the appliance

area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS

• DO NOT try to light any appliance.

• DO NOT touch any electric 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.

C. Use only your hand to push in or turn the gas control

knob. NEVER use tools. If the knob will not push in or
turn by hand, DON'T try to repair it, call a qualified ser­vice technician. Force or attempted repair may result in a
fire or explosion.

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
underwater.

Operating Instructions

1. STOP! Read the safety information above.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition device which
automatically lights the pilot. DO NOT try to light the pilot
by hand.

5. Remove control access panel.

6. Turn gas control knob clockwise till knob stops then
continue to "OFF". DO NOT force.

7. Wait five (5) minutes (longer for propane) to clear out any
gas, then smell for gas, including near the floor. If you
then smell gas, STOP! Follow "B" in the safety informa­tion above on this page. If you don't smell gas, go to next
step.

8. Turn gas control knob counterclockwise to "ON".

9. Replace control access panel.

10. Turn on all electric power to the appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the instructions "To
Turn Off Gas To Appliance" and call your service techni­cian or gas supplier

To Turn Off Gas To Appliance

1. Set the thermostat to lowest setting.

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

3. Remove control access panel.

4. Turn gas control knob clockwise till knob stops,
then continue to "OFF". DO NOT force.

5. Replace control access panel.

BURNER ADJUSTMENT

A. Adjust gas input rate:

1. Consult gas supplier for higher* heating value of gas
(Btu/cu.ft.)

2. Set thermostat high enough so that boiler will remain on
while checking rate.

3. Measure manifold pressure at 1/8" tapping. Correct
manifold pressure for gas used is printed on boiler rat­ing plate. NOTE: Gas pressure may be adjusted by turn­ing pressure regulator screw on combination gas valve
(turn clockwise to increase pressure, counterclockwise
to decrease pressure).
a. Input for PROPANE is approximately at rating shown

on rating plate when manifold pressure is 9-1/2"
water column.