Page 1
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
Page 2
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
Page 3
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.
Page 4
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"
Page 5
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.
Page 6
6 GALAXY
VENT DAMPER INSTALLATION
The vent damper referred to in the following instructions is the
Slant/Fin Corporation vent damper.
I. This device is design certified by C.S.A. for use ONLY on
specific Slant/Fin Corp. gas boiler models. These boilers
must also be equipped with a plate which states that the
boiler must or may be used with a Slant/Fin Corp. automatic
vent damper device and indicates the proper vent damper
model number.
II. A.INSTALLATION INSTRUCTIONS BEFORE YOU START
TO INSTALL
1. Read this installation manual, the "DANGER" plate
attached to the top of the boiler, the "WARNING" on the
wiring diagrams, vent damper carton and operator
cover.
2. Perform pre-installation inspection as required by ANSI
specification Z21.66.
3. Turn off all electrical power, gas supply and wait for system to cool (for previously installed boilers).
4. Select a proper, convenient location (see figures 1 & 2).
5. Carefully unpack the unit. DO NOT FORCE IT OPEN
OR CLOSED! Forcing the damper may damage the
gear train and void the warranty.
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 "RECEPTACLE B" is plugged into "MALE
PLUG" (as described in the installation instructions), and the
vent damper installation and checkout procedures have been
completed. Failure to observe this warning may create a hazardous condition that could cause an explosion or carbon
monoxide poisoning.
B.1. This device must be installed after the appliance draft
hood (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 the damper. (See figures 1 & 2.)
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 access for service.
C.NOW, PROCEED AS FOLLOWS:
1. Remove the front cover of the boiler exposing the wiring
compartment. With all electrical power to boiler off,
locate "MALE PLUG" and "Receptacle A" (see wiring
diagram attached to boiler); a copy of this may also be
found in this manual.
Cut the RED wire connected between numbers 3 and 4
of "RECEPTACLE A" (the only wire connected to this
receptacle) and then disconnect "RECEPTACLE A" from
"MALE PLUG". Remove "RECEPTACLE A" from job
site and discard.
2. Separate the vent pipe directly on top of the draft hood
and place damper in position as shown in figures 1& 2.
The vent damper must be installed so that the damper
position indicator is in a visible location after installation.
The arrow imprint on the damper should point in direc-
Figure 1. Vertical installation of vent damper on Galaxy Boilers
Figure 2. Horizontal or sloping installation of vent damper
* Install operator in any position as shown above. DO NOT install the operator
above the vent pipe (to avoid excessive heat) or below the vent pipe (to avoid
possible condensation damage).
Galaxy
Boiler
Page 7
GALAXY 7
tion of vent gas flow (towards chimney). Re-assemble
the vent piping. Be sure the vent damper is well seated
and fastened with 3 sheet metal screws. Screws should
be no longer than 1/2 inch. See figure 3.
3. Boilers that may have vent damper are factory wired
with plug and "RECEPTACLE A". To install the vent
damper all that is required is removal of the "RECEPTACLE A" and connection of the vent damper harness to
the boiler plug. Boilers that must have a vent damper
are factory wired with plug only. (Remove "RECEPTACLE A" from job site and discard.)
a)Attach the flexible metallic conduit vent damper har-
ness to the right hand side of the jacket by passing
the free end of the harness through the 7/8 diameter
hole in the top of the jacket, and using the BX connector at the free end of the metallic conduit, fasten to
jacket.
b)Connect "RECEPTACLE B" (free end of vent damper
harness) into "MALE PLUG" (see wiring diagram).
4. Restore electrical power and turn on gas supply.
D.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.
3. Replace the front cover of the boiler.
4. Check the trouble-shooting section if problems arise
with the installation.
E.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 the thermostat.
Figure 3.
OPERATING INSTRUCTIONS, BASIC
Before firing boiler, make these checks:
1. Relief valve is installed. Installation of the relief valve shall
be consistent with the ANSI/ASME Boiler Pressure Vessel
Code. Valve opening is NOT closed or reduced in size.
2. Draft hood is installed and vented to chimney.
3. All wiring is completed, following wiring diagram.
4. If a vent damper is added, damper is in full open position. See instructions furnished with vent damper.
5. Using soap solution, check for gas leaks in all gas piping
from meter to boiler pilot and manifold. DO NOT use open
flame.
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
service. Make sure that none of the automatic gas ignition
system components are exposed to water.
Page 8
8 GALAXY
BURNER ADJUSTMENT
A.Adjust gas input rate:
1. Consult gas supplier for 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, counter
clockwise to decrease pressure).
a. Input for PROPANE is approximately at rating shown
on rating plate when manifold pressure is 9-1/2" water
column.
b. Input for NATURAL GAS is approximately at rating
when manifold pressure is 3-1/2" water column, but
should be checked on the gas meter:
Btuh Input = Btuh/cu. ft. x cu. ft. metered in 3 minutes
x 20
SAFETY INFORMATION
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions
exactly, a fire or explosion may result causing property
damage, personal injury or loss of life.
A. This appliance is equipped with an ignition device which
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 under water.
Operating Instructions
1. STOP! Read the safety information on this page.
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 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 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.
FIGURE 4. INTERMITTENT PILOT (IID) SYSTEM FOR BOILERS
EQUIPPED WITH HONEYWELL GAS VALVE VR8204 &
VR8304 (see figures 4 & 5).
FIGURE 5. Gas Valve VR8204 & VR8304
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 to "OFF".
Do NOT force.
5. Replace control access panel.
Page 9
GALAXY 9
C. Main Burner Ignition Check-out and Pilot Adjustment
1. The pilot flame must not smother or snuff out when tested
as follows:
a. Main burner ignition from cold start-repeat.
b. Continued operation of main burner.
c. Main burner ignition with appliance at maximum operating
temperature after prolonged operation.
NOTE: Observe operation of the pilot burner with appliance doors in the final operating position. Use of a mirror
may be helpful.
2. Safety Shutdown Check-out
a. Make certain the pilot burner holds in, and opens properly,
when the pilot is burning normally; and that safety shutdown occurs within 2-1/2 minutes after the pilot flame is
extinguished. Observe operation for at least one cycle
under automatic control to be sure the system is functioning normally.
b. For proper operation the pilot should engulf the flame sen-
sor as shown below.
c. To adjust pilot, turn pilot flow adjustment screw on valve
clockwise or counterclockwise to give a steady flame
enveloping 3/8" to 1/2" of the tip of the flame sensor.
Note that turning the pilot adjustment screw clockwise
will decrease the pilot flame.
d. Check safety shutdown of gas valve by following proce-
dure outlined "CARE AND MAINTENANCE" section.
CONTROLS, SAFETY CHECK
Check all safety controls not previously mentioned. Also, follow
directions in "CARE AND MAINTENANCE" section, paragraphs
IV through VII.
These boilers are equipped with both a draft hood blocked vent
safety switch and a rollout safety switch. The blocked vent safety
switch is located on the draft hood flue stack. This is a manual
reset control used to prevent excessive spillage of flue gases from
the draft hood. The rollout safety switch is a single use (one time)
thermal fuse to prevent the boiler from operating if flue passages
are blocked. If either of these devices shut down the burners, follow instructions in the section "To Turn Off Gas To Appliance" and
call your service technician or gas supplier.
CARE AND MAINTENANCE
WARNING: THE FLOW OF COMBUSTION AND VENTILATING
AIR TO THE BOILER SHOULD NOT BE OBSTRUCTED.
This section must be brought to the attention of the owner by the
installer so that the owner can make the necessary arrangements
with a qualified service agency for the periodic care and maintenance of this boiler. The installer must inform the owner that the
gas supplier can recommend a number of qualified service agencies. The installer must also inform the owner that the lack of proper care and maintenance of this boiler and any fuel burning equipment may result in a hazardous condition.
(Continued on next page)
300 15.00
325 16.25
350 17.50
375 18.75
399 19.95
Boiler rated input in
cu. ft./hr. of 1000 Btu/cu.ft.
Natural Gas
Cubic Feet Gas Consumption
1000 Btu/cu. ft. gas, in 3 min-
utes, at rated output
B.Main Burner
1. Fire the boiler continuously for at least 15 minutes, to reach
burner operating temperature.
2. Observe the flames, all burners. The base of all flame jets
should be blue. The tips should be blue shading to orange.
NOTE: Dust, disturbed by any movement, will cause bright
orange flames. Wait for dust to settle.
3. For one burner, close the air shutter until some of its flame
jet tips turn yellow-white, indicating insufficient primary air.
Then open shutter until whitish tips disappear completely.
Set all burner shutters to the same opening. Observe to
make sure that no yellow-white tips appear over any portion
of the flame. Small yellow tips at the pilot location are permitted.
NOTE: This adjustment method gives MINIMUM primary air
setting for safe combustion. DO NOT attempt to make this
adjustment unless burners are at operating temperature.
Adjustment should be made with jackets in final operating
position. Use of mirror may be helpful to observe flames.
Note that burner ports are on top of main burner tube.
Example #1:
For 1000 Btu/cu. ft. gas, this becomes:
Btuh Input = cu. ft. metered in 3 minutes x 1000
Btu/cu.ft. x 20
Example #2:
For 1050 Btu/cu. ft. gas, this becomes:
Btuh Input = cu. ft. metered in 3 minutes x 1050
Btu/cu.ft. x 20
4. The higher* heating value of gas varies substantially for
different localities. Consult with Slant/Fin’s Technical
Service Dept. for re-orificing procedures if any of the following apply:
a. Boiler (burner) is overfiring. CAUTION! National Fuel
Gas Code (ANSI Z223.1-latest edition) does NOT
permit firing at a higher input rate than the input rate
indicated on the boiler rating plate in order to avoid
hazardous conditions such as explosion or carbon
monoxide poisoning.
b. Poor higher* heating value of gas is causing the actu-
al input to be substantially lower than the rating plate
indication.
* “Higher heating value” of gas is commonly known as “heating value”
GAS RATE TABLE
The gas metered in 3 minutes to obtain rated input for each boiler
model, using 1000 Btu/cu. ft. gas is tabulated in gas rate table.
Page 10
10 GALAXY
I. GENERAL MAINTENANCE
These operations are recommended to be performed at regular
intervals:
A.BOILER HEATING SURFACES: clean off all coatings found.
B.BOILER CONTROLS: check contacts, settings, correct func-
tioning.
C.PIPING: check piping and accessories for leaks.
D.CHIMNEY and BREECHING: check for obstructions and
leaks.
E.BOILER ROOM AIR SUPPLY: check air vents for continued
POSITIVE supply of air as required. Air needs are greatest in
cold weather. Air vents must be open and free of obstruction.
F. WATER SYSTEM: check
1. System to be full of water, and pressure to remain stable at
correct setting on gauge.
2. Air-control system: noise and air binding in radiation should
not occur.
3. Water lines: slightest leaks should be corrected.
4. Low water cut-off, for operation (see instructions furnished
with unit.)
II. WATER LEVEL CHECK DURING HEATING SEASON:
Regular loss of water from water boiler system may indicate
either a system leak, or a faulty air-control system, or a faulty
automatic fill valve.
III. ANNUAL INSPECTION AND CLEANING:
A.It is important that this boiler be inspected by a competent
serviceperson to help insure safe and reliable operation.
B.Check for gas leaks from valve and gas piping to burners and
pilot. If leaks are found, repair or replace as required.
C.This inspection should include:
1. Controls check. See SAFETY CHECK, IV.
2. Recheck of input gas rate to burners. See "Initial Start"
paragraph in "Operating Instructions" section.
3. Re-adjusting for best flame characteristics of main flame
and pilot.
See "Initial Start" paragraph in "Operating Instructions" section and see "Burner Adjustment" section.
4. Burner and boiler flue passage cleanliness: BURNER AND
FLUE CLEANING (see sketch). It is suggested that paper
be placed on burners to collect any foreign material in
cleaning flues.
5. Remove draft hood, jacket top and flue cover.
6. Use wire brush to clean flueways.
7. Replace flue cover and re-seal with furnace cement.
Replace jacket top and draft hood and reconnect to smoke
pipe, using screws. Remove and dispose of paper and
accumulated material.
8. If burner surfaces are not clean, or if uneven flame indicates plugged burner ports, remove and clean burners.
NOTE—TO REMOVE BURNERS:
a. Remove holding wire clip at orifice.
b. Disconnect pilot at pilot mount, or disconnect pilot gas line at
gas valve, before removing burners next to pilot.
c. Lift rear of burner and remove burner from orifice.
d. Clean and replace burners* and pilot. Adjust burners as
described on “Burner Adjustment”.
* To clean burners run a clean flue brush up the tube until all
foreign matter is removed.
Boiler Cleaning
IV. SAFETY CHECK FOR CONTROL SYSTEM
A.High limit control test: Set thermostat high enough for boiler
water temperature to reach high limit control setting. When
this temperature is reached, the high limit switch should open,
and the main gas valve should close automatically. If the high
limit does not close the main gas valve, the valve, the high
limit or the wiring is faulty. Repair or replace immediately.
B.Gas valve safety shutdown test:
With main burners firing, disconnect the ignition cable from
the Ignition Control. The gas valve should shut off the main
burners. If the gas valve fails to shut down main burners when
the test is performed, replace the gas valve.
C.Check for gas leaks from valve and gas piping to burners and
pilot. If leaks are found, repair or replace as required.
V. A. Providing Protection from Freezing.
Anti-freeze is sometimes used in hydronic heating systems to
protect against freeze-up in the event of power failure or control shutdown when the building is unoccupied. It should be
recognized that unless the building is kept above freezing
temperature by some means, the plumbing system is not protected.
Two types of anti-freeze may be used: ETHYLENE GLYCOL,
used in automobiles, has desirable properties, but is toxic. Its
use may be prohibited when system water/glycol solution is in
contact with a potable water vessel (as with a tankless
heater). PROPYLENE GLYCOL is used in the quick-freeze
food industry; it is practically non-toxic. Its use may be permitted when tankless heaters are used. When anti-freeze must
be used, inhibited propylene glycol is recommended. Useful
information on the characteristics, mixing proportions, etc. of
glycol in heating systems is given in Technical Topics No. 2A,
available from the Hydronics Institute 34 Russo Place,
Berkeley Heights, NJ 07922. Consult glycol manufacturers for
sources of propylene glycol.
B.Water Treatment:
A good water treatment program will not only extend the useful life of this boiler but it will also save much of the time and
expense of repairs made necessary by preventable occurrences.
A reputable water treatment company should be consulted to
evaluate and determine the best overall treatment program for
your boiler equipment.
VI. KEEP THE BOILER AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS, GASOLINE, AND OTHER FLAMMABLE
VAPORS AND LIQUIDS.
Page 11
GALAXY 11
SEQUENCE OF OPERATION FOR GALAXY BOILERS EQUIPPED WITH
INTERMITTENT PILOT IGNITION SYSTEM (IID).
HIGH-LIMIT CONTACTS CLOSED?
VENT DAMPER RELAY ENERGIZED.
VENT DAMPER MOTOR MOVES OPEN VENT DAMPER.
END SWITCH CLOSES.
IGNITION CONTROL ENERGIZED
SPARK GENERATOR MODULE POWERED
IGNITION SPARK STARTS AND PILOT VALVE OPERATOR OPENS..
L.P. PROPANE GAS
(S8600M & S8670E) IGNI-
TION TRIAL CONTINUES
FOR 90 SECONDS. AFTER
TRIAL FOR IGNITION, SYS-
TEM SHUTS OFF. AFTER 5
MINUTES MODULE RE-
INSTATES TRIAL FOR IGNI-
TION. IF PILOT FLAME NOT
ESTABLISHED, IGNITION
TRIAL, SYSTEM SHUT-OFF
AND 5 MINUTES WAIT
SEQUENCE REPEATS
CONTINUOUSLY.
NATURAL GAS
IGNITION SPARK CON-
TINUES. PILOT VALVE
REMAINS OPEN UNTIL
SYSTEM IS RESET.
SPARK GENERATOR OFF. MAIN VALVE OPERATOR OPENS. MODULE MONITORS PILOT FLAME.
THERMOSTAT CALLS
FOR HEAT
MODELS WITH
VENT DAMPERS
THE PILOT FLAME ESTABLISHED?
WHEN THERMOSTAT IS SATISFIED OR WHEN HIGH LIMIT, OR LOW WATER CUT-OFF CONTACTS ARE OPEN, VALVE OPERA-
TORS CLOSE, VENT DAMPER CLOSES. SYSTEM GOES TO STANDBY.
NO FURTHER
ACTION
NO
NONO
YES
YES
Page 12
12 GALAXY
CAUTION: Label all wires prior to disconnection when servicing control.
Wiring errors can cause improper and dangerous operation. “Verify proper operation after servicing.”
FIGURE 6. Schematic wiring diagram
Page 13
GALAXY 13
BURNERS FAIL TO OPERATE
CAUSE
1. Safety pilot out, or flame too low.
2. Gas supply valve shut off.
3. Electric switch open.
4. Blown or defective line fuse.
5. Operating or limit control contacts open or dirty.
6. Defective gas valve or pressure regulator; or plugged bleed
line.
7. Defective low voltage transformer.
8. Obstruction at main burner orifice.
9. Break in wiring or loose contact at control terminals.
10. Improper wiring.
11. Improper controls.
12. Rollout or blocked vent safety switch open.
BURNERS WILL NOT SHUT OFF
CAUSE
1. Defective operating control, gas valve, or high limit control.
2. Improper wiring or short circuit.
FLASH BACK - BURNING AT ORIFICES
CAUSE
1. Manifold gas pressure too low.
2. Improper primary air adjustment.
3. Gas regulator bleed too slow.
4. Burrs on orifice.
5. Improperly drilled orifice plugs.
6. Leaking automatic gas valve.
7. Adverse draft condition in boiler room.
8. Low main gas pressure.
9. Safety pilot improperly installed.
DELAYED IGNITION
CAUSE
1. Pilot flame too low.
2. Pilot burner ports or pilot orifice clogged.
3. Burners or orifices out of alignment.
4. Excessive primary air.
5. Excessive burner input.
6. Adverse draft condition in boiler room.
FUMES AND GAS ODORS
CAUSE
1. Leaks in gas piping or accessories.
2. Gas leaks in service line or meter connections.
3. Blocked chimney.
4. Boiler flueways blocked with soot.
5. Undersized breeching or too many turns in breeching.
6. Adverse draft condition in boiler room.
7. Overfiring.
CONDENSATION IN BOILER FLUES OR IN VENT SYSTEM
CAUSE
1. Underfiring.
2. Boiler water maintained at too low a temperature level.
3. Long horizontal run of smokepipe.
4. Inadequate chimney or venting system.
REMEDY
1. Check, clean, re-light. See instructions.
2. Open gas valve(s).
3. Close Switch.
4. Replace fuse.
5. Check Control. Clean contacts or replace control.
6. Repair or replace.
7. Replace aquastat.
8. Check, clean and reinstall.
9. Check with test-light and correct.
10. Check and correct in accordance with wiring diagrams
included with appliance instructions.
11. Install proper controls.
12. Replace rollout switch (inspect flue passages prior to
replacement) or reset blocked vent safety switch by
depressing the reset button
REMEDY
1. Check, repair or replace.
2. Check wiring and controls.
REMEDY
1. Adjust to proper manifold pressure.
2. Adjust air to produce soft, clean flame.
3. Adjust bleed opening.
4. Remove burrs.
5. Install orifice plugs with proper drilling.
6. Repair or replace.
7. Check air supply and venting system.
8. Contact utility.
9. Correct to manufacturer's recommendations.
REMEDY
1. Increase gas supply to pilot.
2. Clean ports or orifices.
3. Realign burners or manifold.
4. Adjust primary air shutters.
5. Check and reduce to input shown on rating plate.
6. Check air supply and venting system.
REMEDY
1. Locate leaks and repair.
2. Close service supply valve - shut down appliance and notify utility.
3. Check and repair chimney.
4. Clean flueways and adjust burners as described in the
installation instructions.
5. Check manufacturer's recommendations.
6. Check air supply and venting system.
7. Adjust gas input to that shown on boiler rating plate.
REMEDY
1. Increase firing rate to that shown on rating plate.
2. Set low limit controls to maintain a higher water temperature. If boiler is not equipped with low limit replace with
one which has a combination low limit/high limit aquastat.
3. Relocate boiler or insulate breeching.
4. Check chimney and venting recommendations.
GENERAL TROUBLE SHOOTING GUIDE FOR SERVICEPEOPLE
Page 14
14 GALAXY
PIPING A HEATING — COOLING SYSTEM
TO A WATER BOILER AND CHILLER
Figure below illustrates a method of piping a heating-cooling
system to a water boiler and a chiller. Hand valves (shown) or
automatic valves must be installed to prevent circulation of
chilled water in the boiler or hot water in the chiller.
IF REPLACEMENT PARTS ARE NEEDED
When parts are needed, refer to boiler model and serial number shown on the boiler name/rating plate. Refer to the following
parts lists for part numbers; publication number GG-10PL for
Galaxy GG Series. Whenever possible refer to the original order
by number and date.
Control identification and replacement should not be attempted
by unskilled personnel. Only simple, easily identified controls
and parts may be obtained locally. All other controls and parts
should be identified by and ordered from Slant/Fin.
Relief/Safety valves must be ASME rated for the pressure and
gross output of the boiler.
Replacement parts are available from:
Slant/Fin Corp.
100 Forest Drive
Greenvale, NY 11548
Attn: Technical Service Dept.
The air-control system and pressure control system must operate with chiller only, or the boiler only, being valved to the piping
system. Separate control devices on the boiler and chiller may
be used, or a single set of air and pressure controls on the
common piping may be preferred.
If the boiler is used to supply hot water to heating coils in air
handling units, flow control valves or other devices must be
installed to prevent gravity circulation of water in the coils during the cooling cycle.
GENERAL TROUBLE SHOOTING GUIDE FOR SERVICEPEOPLE
Page 15
GALAXY 15
APPENDIX A
Removal of Existing Boiler from Common Vent System
"At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in
operation."
(a) Seal any unused openings in the common venting system.
(b) Visually inspect the venting system for proper size and hori-
zontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could
cause an unsafe condition.
(c) Insofar as is practical, close all building doors and windows
and all doors between the space in which the appliances
remaining connected to the common venting system are
located and other spaces of the building. Turn on clothes
dryers and any appliance not connected to the common
venting system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will operate at maximum speed. DO NOT operate a summer exhaust fan.
Close fireplace dampers.
(d) Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance will
operate continuously.
(e) Test for spillage at the draft hood relief opening after 5 min-
utes of main burner operation. Use the flame of a match or
candle, or smoke from a cigarette, cigar or pipe.
(f) After it has been determined that each appliance remaining
connected to the common venting system properly vents
when tested as outlined above, return doors, windows,
exhaust fans, fireplace dampers and any other gas-burning
appliance to their previous conditions of use."
(g) Any improper operation of the common venting system
should be corrected so the installation conforms with the
National Fuel Gas Code, ANSI Z223.1-latest edition. When
resizing any portion of the common venting system, the
common venting system should be resized to approach the
minimum size as determined using the appropriate tables in
Appendix G in the National Fuel Gas Code, ANSI Z223.1latest edition.
Page 16
©Slant/Fin Corp. 2015 • Printed in U.S.A. 1115 • Publication GG-40S
U.S.A.
Slant/Fin Corporation • 100 Forest Drive
Greenvale, NY 11548 • 516-484-0933
www.slantfin.com
Canada
Slant/Fin LTD/LTEE • 400 Ambassador Drive,
Mississauga, Ontario L5T 2 J3 • 905-677-8400
www.slantfin.ca
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