Slant/Fin Galaxy GG-300 Installation And Operating Instructions Manual
CONTENTS..........................................................................PAGE
Dimensions ..................................................................................2
Gas Orifice Sizes ........................................................................2
Installation Requirements:
Boiler Location ........................................................................3
Boiler Foundation....................................................................3
Chimney Requirements ..........................................................3
Minimum Clearance ....................................................................4
Vent Piping ..............................................................................4
Gas Piping ..................................................................................4
Electrical Controls and Wiring ................................................5
Boiler Room Air Supply and Ventilation ..................................5
Draft Hood Installation ............................................................5
Piping at Boiler—Water Boilers ..............................................5
Vent Damper Installation ........................................................6
Operating Instructions..................................................................7
Filling and Venting Water Systems..........................................7
Initial Start, Safety & Lighting Instructions ..............................8
Burner Adjustment, Checking Gas Input ................................8
Controls, Safety Check ..........................................................9
Care and Maintenance ................................................................9
Safety Check for Control System ..........................................10
Protection From Freezing......................................................10
Water Treatment....................................................................10
Sequence of Operations ............................................................11
Wiring Diagram ..........................................................................12
Trouble Shooting Guide ............................................................13
Piping a Heating and Cooling System ......................................14
Replacement Parts ....................................................................14
Appendix A ................................................................................15
IMPORTANT
READ ALL OF THE FOLLOWING WARNINGS
AND STATEMENTS BEFORE READING THE
INSTALLATION INSTRUCTIONS
WARNING
LIQUEFIED PETROLEUM (L.P.)
PROPANE FIRED GAS BOILERS
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.
WARNING
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.
HOT WATER—Models GG-300 through GG-399HES
INSTALLATION AND OPERATING INSTRUCTIONS
GALAXY
GAS-FIRED CAST IRON BOILERS FOR NATURAL
AND L.P. PROPANE GASES
INTERMITTENT PILOT IGNITION
™
Printed in U.S.A. 1115 PUBLICATION GG-40S
Part No. 41-2842
Heating Contractor
Address
Phone Number
Boiler Model Number
Boiler Serial Number
Installation Date
CANADIAN ENERGY
PERFORMANCE
VERIFIED
RENDEMENT
ENERGETIQUE
VERIFIE
2 GALAXY
ORIFICE SIZES indicated for Sea Level are
factory installed in boiler unless otherwise
specified by the local authority. See VII, page
8 for burner input adjustment.
GAS VALVE CONNECTION Size may be
3/4" or 1/2" depending upon configuration
(natural, L.P.).
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 Dimension “C” or larger. Larger
diameter &/or height may be required if two
or more boilers or a boiler and another appliance are vented to a single chimney.
ORIFICE SIZES AT HIGH ALTITUDES
INCLUDES 4% INPUT REDUCTION FOR EACH 1000 FEET
ELEVATION — FEET
BOILER MODEL
GG
Except GG-399H
GG-399H
GAS TYPE
Natural
Propane
Natural
Propane
Orifice
Size for
Sea Level
41
54
40
53
42
54
41
54
42
55
42
54
42
55
42
54
43
55
42
54
43
55
43
54
44
55
43
54
44
56
44
55
45
56
44
55
46
56
45
55
2,000
3,000
4,000
5,000
6,000 7,000 8,000 9,000 10,000
A
B
C
D
E
F
G
H
J
K
GG-300
33-1/4
26-3/4
8
59-5/8
17
14-3/4
1-1/2
1-1/2
2-3/4
9-1/4
GG-325
33-1/4
26-3/4
8
66-1/8
17
14-3/4
1-1/2
1-1/2
2-3/4
9-1/4
GG-350
36-1/2
30
9
66-1/8
22-1/2
16-1/4
1-1/2
1-1/2
2-3/4
9-1/4
GG-375H
36-1/2
30
9
59-5/8
15
16-1/4
1-1/2
1-1/2
2-3/4
9-1/4
GG-399H
36-1/2
30
10
66-5/8
22
16-1/4
1-1/2
1-1/2
2-3/4
9-1/4
GG SERIES HOT WATER BOILERS - DIMENSIONS IN INCHES
FRONT VIEW
LEFT SIDE FRONT VIEW
RIGHT SIDE
RIGHT SIDE
DIMENSIONS
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 requirements in this Slant/Fin instruction book. Installation and service
to be performed by a qualified installer, service agency or the
gas supplier.
NATURAL GAS FIRED BOILER LOCATION—
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.
CHIMNEY REQUIREMENTS—
A. Galaxy boilers may be vented into a masonry vitreous tile-
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
with Part 7, Part 11 and Appendix G of the National Fuel
Gas Code ANSI Z223.1, NFPA 54, -latest 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
more sides below the roof line (exterior chimney), ONE of
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 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 15 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.
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 require-
ments.
* 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.
WARNING
SPECIAL ATTENTION FOR LIQUEFIED PETROLEUM
(L.P.) PROPANE GAS-FIRED BOILER INSTALLATIONS
LPG appliances (boilers) shall be installed in accordance
with applicable provisions of NFPA 58 ( Liquefied Petroleum
Gas Code) latest edition for installations in US and
CAN/CGA B149.1 latest edition for installations in Canada.
Liquefied Petroleum (LP) propane gas is heavier than air
therefore Propane gas accumulate at floor level. If you sus-
pect a leak, do not attempt to operate boiler. A spark or
flame from the appliance (boiler) or other sources may ignite
the accumulated propane gas causing an explosion or fire.
It is recommended that inspections for gas leaks be per-
formed periodically by licensed professional and that leak
detection devices be installed as a further safety measure.
4 GALAXY
MINIMUM CLEARANCES FROM COMBUSTIBLE
CONSTRUCTION —
A. Minimum boiler clearances shall be as follows:
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
or ceiling boards may be not less than 1/2". Each such opening shall be
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, con-
sistent 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 sup-
ported 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—
A. Local installation codes apply. The pipe joint compound used
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
main shut-off valve that may be specified locally.
Selecting pipe size for natural gas:
1. Measure or estimate the length of piping from the meter to
the installation site.
2. Consult gas supplier for heating value of gas (BTU/cu. ft.).
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.
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.
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
Length
of Pipe
in Feet
Gas Flow In Piping -- cu. ft. per hr.
Iron Pipe Size (Ips)—inches
Gas flow = 300,000 BTU/hour = 294 cu. ft. per hour
1020 BTU/cu. ft.
GALAXY GG SERIES
MODELS GG-300 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"
GALAXY 5
ELECTRICAL WIRING
DANGER: Before wiring, always turn off electric power supply,
otherwise shock or death can result.
Power Supply
A separately fused circuit is recommended. Use a standard
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 6). 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 Code, ANSI/NFPA
70-latest edition.
BOILER ROOM AIR SUPPLY AND VENTILATION
An ample supply of air is required to obtain combustion and
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
insulated, caulked and weather-stripped, now or later on, direct
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 opening will be 100 square inches. A grilled opening 10" x 10" has
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.
Protect against closure of openings by snow and debris.
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,
PIPING AT BOILER — WATER PIPING
I. CIRCULATING SYSTEMS
A.Packaged water boilers are equipped with a water circulat-
ing pump, mounted to return the water into the boiler. For
some installations, the pump should be on
the supply main. See PUMP LOCATION.
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 illustration.
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. See illustration.
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).
C.On a hot water boiler installed above radiation level,the
boiler must be provided with a low water cut-off device at
the time of installation by the installer.
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