Slant/Fin GXH-190 User Manual

CONTENTS .........................................................................PAGE
Dimensions..................................................................................2
Installation Requirements:
Boiler Location........................................................................3
Boiler Foundation....................................................................3
Chimney Requirements............................. .............................3
Minimum Clearance.....................................................................3
Vent Piping..............................................................................4
Gas Piping...................................................................................4
Draft Hood Installation.............................. ..............................5
Vent Damper Installation.........................................................6
Electrical Controls and Wiring.................... .................................8
Boiler Water Temperature Control.................... ....................12-16
Water Piping..............................................................................17
Sequence of Operation of Galaxy Boilers.................................20
Care and Maintenance:
General Maintenance.................................. .........................22
Water Level Check................................................................23
Annual Inspection and Cleaning...........................................23
Safety Check for Control System..........................................23
Protection from Freezing, Water Treatment ..........................23
Keeping Area Clear ..............................................................23
Troubleshooting Guide...............................................................24
Piping a Heating and Cooling System.......................................25
Replacement Parts....................................................................25
Appendix A ................................................................................25
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.
Printed in U.S.A. 1013 PUBLICATION GG-41 Rev. B
Part No. 41-0879
INSTALLATION AND OPERATING INSTRUCTIONS
Models GG-75H through GG-399H and Models GXH-105 through GXH-190
GALAXY
GAS-FIRED CAST IRON BOILERS FOR
NATURAL AND L.P. PROPANE GASES
Heating Contractor
Address
Phone Number
Boiler Model Number
Boiler Serial Number
Installation Date
HOT WATER BOILERS
WARNING
SEE “WARNING” ON PAGE 3 FOR LIQUEFIED PETROLEUM
(L.P.) PROPANE GAS-FIRED BOILERS
IMPORTANT
READ ALL OF THE FOLLOWING WARNINGS
AND STATEMENTS BEFORE READING THE
INSTALLATION INSTRUCTIONS
2 GALAXY
ORIFICE SIZES indicated for Sea Level are factory installed in
boiler unless otherwise specified by the local authority. See VII, page 21 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 Dimen­sion “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.
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
3
4 193⁄4 193⁄4 23 23 261⁄2 261⁄2 293⁄4 293⁄4 331⁄4 361⁄2 361⁄2 361⁄2
B 131⁄4 131⁄4 131⁄4 161⁄2 161⁄2 20 20 231⁄4 231⁄4 263⁄4 30 30 30
C 566677788891010
D 46
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
E 63⁄4 13 15 13 13 16 16 17 17 17 221⁄2 15 22
F 8889
3
4 93⁄4 111⁄4 111⁄4 13 13 143⁄4 161⁄4 161⁄4 161⁄4
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
GXH-105 GXH-125 GXH-150 GXH-170 GXH-190
A 23 23 261⁄2 261⁄2 261⁄2 B 161⁄2 161⁄2 20 20 20 C 5677 7 D 46
3
8 531⁄4 551⁄2 551⁄2 551⁄2
E 63⁄4 13 14 14 14 F 9
3
4 93⁄4 111⁄4 111⁄4 111⁄4
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
GG SERIES HOT WATER BOILERS - DIMENSIONS IN INCHES
GXH HOT WATER BOILERS - DIMENSIONS IN INCHES
FRONT VIEW
All GG and GXH
RIGHT SIDE
GG / GXH-PT
GG Natural 42 43 43 43 43 44 44 45 46 47
Except GG-399H
Propane 54 54 55 55 55 55 55 56 56 56
GG-399H
Natural 40 41 42 42 42 43 43 44 44 45
Propane 53 54 54 54 54 54 54 55 55 55 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
Natural
GG-350H
Gas* 43 44 44 44 45 45 46 47 47 48
BOILER MODEL GAS TYPE 2,000
ELEVATION–FEET
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
Orifice
Size for
Sea Level
*For L.P. Propane gas, consult factory.
BOILER DIMENSIONS
VENT DAMPER
DRAFT HOOD
SUPPLY
BLOCKED VENT
IGNITION CONTROL
GAS VALVE
BURNERS
SAFETY SWITCH
PRESSURE RELIEF VALVE
TEMPERATURE/ PRESSURE GAUGE
WATER TEMPERATURE CONTROL
TRANSFORMER 120/24V
RETURN
ROLLOUT SAFETY SWITCH
GAS
MANIFOLD
Location and identification of parts
GALAXY 3
GALAXY GG SERIES
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.
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 sus­pect 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 per­formed periodically by licensed professional and that leak detection devices be installed as a further safety measure.
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 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 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:
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. DO NOT place boilers above floor area containing radiant tubing.
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
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.
GXH SERIES
MODELS GXH-105 THROUGH GXH-190 MINIMUM CLEARANCE FOR COMBUSTIBLE CONSTRUCTION. MINIMUM CLOSET CLEARANCE.
Front 6" Rear 6" Left Side 6" Right Side 18" Top 36" Flue Connector 6" Type 'B' Vent 1"
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 5
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,
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 spe­cific Slant/Fin Corp. gas boiler models. These boilers must 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. A. INSTALLATION INSTRUCTIONS BEFORE YOU START TO
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.
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).
4. Carefully unpack the unit. DO NOT FORCE IT OPEN OR CLOSED! Forcing the damper may damage the gear train and void the warranty.
Figure 1. Vertical installation of vent damper on Galaxy Boilers
Figure 2. Horizontal or sloping installation of vent damper
Figure 3.
* 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
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.
B. 1. This device must be installed after the boiler 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 vent damper. (See figure 1 and 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 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
ELECTRICAL WIRING
DANGER: Before wiring, always turn off electric power supply,
otherwise shock or death can result.
1. 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 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 Code, ANSI/NFPA 70-latest edition.
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 the thermostat.
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.
5. Indirect External Water Heater
If system includes indirect water heater, the indirect signal must be separated from heating zones(s) system. See figure 6 and 8. 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.
Note: For single heating zone with external indirect water heaters, see figure 9.
Figure 4
SCHEMATIC WIRING DIAGRAM FOR GALAXY GG & GXH
HYDROLEVEL HYDROSTAT CONTROL
24V
THERMOSTAT
BLACK
I
HOT
120V/60Hz
NEUTRAL
WIRE LEGEND: FACTORY WIRED FIELD WIRED, FIELD SUPPLIED
: PROVIDE DISCONNECT MEANS AND
I
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.
CAUTION:
LABEL ALL WIRE PRIOR TO DISCONNCTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. "VERIFY PROPER OPERATION AFTER SERVICING".
JUNCTION
BOX
GREEN
WHITE
Z T TV
L1
MODEL 3200
LO TEMP
C2
L2
E T
I H
W
CIRCULATOR
PLUG
B1
C1
K C A
L
B
ECONOMY
HI TEMP
B2 I1
RED
BLOCKED VENT SAFETY SWITCH
ELECTRIC
IGNITION
PILOT
PILOT GAS PIPE
I2
BLUE
RED
ROLL-OUT SWITCH
IGNITOR CABLE
VENT DAMPER
HARNESS
HONEYWELL IGNITION MODULE
24V(GND)
24V
RED
GAS VALVE
GND
MV
MV
MV/PV
PV
GND
(BURNER)
GREEN
PV
MV-PV
BLK
WHITE
RED
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.
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