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