Slant/Fin GXHA-200 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

Electrical Controls and Wiring.................... ............................5

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

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

Piping at Boiler—Steam Boilers................... ..........................6

Steam Controls Assembly and Installation.............................6

Piping a Steam Boiler.........................................................6,7

Vent Damper.......................................... ..............................8,9

Operating Instructions:

Filling and Venting Steam Systems...................................9-10

Initial Start, Safety and Lighting Instructions...................10-11

Burner Adjustment, Checking Gas Input...... ........................11

Controls, Safety Check.........................................................12

Low Water Cut-off Check-Out....................................................12

Pressure Control Check-Out .....................................................12

Blowing Off a Steam Boiler........................................................13

Care and Maintenance.................................. ............................14

Safety Check for Control System..........................................14

Water Treatment....................................................................14

Sequence of Operations............................................................15

Wiring Diagrams...................................................................16-17

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

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

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

IMPORTANT

READ ALL OF THE FOLLOWING WARNINGS AND

STATEMENTS BEFORE READING THE

INSTALLATION INSTRUCTIONS

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. 1114 PUBLICATION GGS-41

Part No. 41-0881

INSTALLATION AND OPERATING INSTRUCTIONS

LOW PRESSURE STEAM—Models GXH-230 through GXH-300H
LOW PRESSURE STEAM—Models GXHA-100 through GXHA-200

GALAXY

GAS-FIRED CAST IRON BOILERS FOR
NATURAL AND L.P. PROPANE GASES

STEAM BOILERS

™

Heating Contractor

Address

Phone Number

Boiler Model Number

Boiler Serial Number

Installation Date

WARNING

SEE “WARNING” ON PAGE 3 FOR LIQUEFIED

PETROLEUM (L.P.) PROPANE GAS-FIRED BOILERS

2 GALAXY STEAM BOILER

ORIFICE SIZES indicated for Sea Level are factory installed in

boiler unless otherwise specified by the local authority.
See VII, page 11 for burner input adjustment.

GAS VALVE CONNECTION Size is 1/2" f.p.t. for all sizes.
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.

GXHA-100 GXHA-120 GXHA-160 GXHA-200

GXH-230 GXH-250 GXH-275 GXH-300H

A ––––29

3

⁄4 321⁄2 321⁄2 321⁄2

B 161⁄2 161⁄2 20 231⁄4 231⁄4 26 26 26
C 5667 777 9
D ––––55

1

⁄2 551⁄2 551⁄2 591⁄8

E – – – – 14 14 14 15
F 10 10 11

3

⁄4 131⁄2 13 143⁄4 143⁄4 143⁄4

G ––––1

1

⁄2 11⁄2 11⁄2 11⁄2

H ––––2

1

⁄2 21⁄2 21⁄2 21⁄2

J –– ––3

1

⁄2 31⁄2 31⁄2 31⁄2

K ––––9

3

⁄4 93⁄4 93⁄4 93⁄4

M 285⁄8 285⁄8 285⁄8 285⁄8 ––– –

GXH AND GXHA SERIES STEAM BOILERS - DIMENSIONS IN INCHES

RIGHT SIDE

GXH-PZT-PPZT

RIGHT SIDE

GXH-PZ

GXH-230 Natural 44 45 45 45 46 47 47 48 48 49
through 275 Propane 54 54 55 55 55 55 55 56 56 56

GXH-300H Natural

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

GXHA

Natural 45 46 47 47 47 48 48 49 49 50

Propane 55 55 55 55 56 56 56 56 56 57

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

GXHA Series

GALAXY STEAM BOILER 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 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 following tables and paragraphs 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.

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.

4 GALAXY STEAM BOILER

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, 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—

A. Local installation codes apply. The pipe joint compound used

on threads must be resistant to the action of liquefied petro-

leum 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 GXH-300H 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 GXHA SERIES

MODELS GXH-230 TO
GXH-300H, MINIMUM
CLEARANCE FOR
COMBUSTIBLE CON­STRUCTION.
MINIMUM ALCOVE
CLEARANCE.
Front Alcove
Rear 6"
Left Side 6"
Right Side 18"
Top 36"
Flue Connector 6"
Type 'B' Vent 1"

MODELS GXHA-100,
GXHA-120, GXHA-160
& GXHA-200
MINIMUM CLEARANCE
FOR COMBUSTIBLE
CONSTRUCTION.
CLOSET AND ALCOVE
CLEARANCE.
Front 6"
Rear 6"
Left Side 6"
Right Side 18"
Top 18"
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 STEAM BOILER 5

ELECTRICAL CONTROLS AND WIRING—

A. The electrical power to the boiler must be on a separately

fused and live circuit.

B. If an external electrical source is utilized, the boiler, when

installed, must be electrically grounded in accordance with
the requirements of the authority having jurisdiction or, in
absence of such requirements, with the National Electrical
Code, ANSI/NFPA No. 70-latest edition.

C. Basic control wiring diagrams are given on pages 16-17.

Other control systems may be factory supplied, see User's
Information Manual and Instructions packed with control
system supplied.

D. After placing the boiler in operation, the safety shut-off

device must be tested. See page 12 safety check.

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.

SPECIAL FLUSHING INSTRUCTIONS

Installation of new boiler may break loose a heavy
accumulation of sediment and scale from old piping
and radiators. It is extremely important to blow
down your McDonnell Cut-off 67 more frequently
the first week.
First week — 3 times
Thereafter — at least once a week
* Exception: McDonnell Cut-off 42A must be blown
down daily.
See "CARE AND MAINTENANCE" for instructions.

Steam Control Assembly

6 GALAXY STEAM BOILER

PIPING A LOW PRESSURE STEAM BOILER

Boilers must be piped with good engineering practice and must
conform to the requirements of ANSI/ASME Boiler and
Pressure Vessel Code section IV and to the authority having
jurisdiction.

NOTES:

1. Slant/Fin makes no recommendation, nor does Slant/Fin
imply that One Pipe Parallel and Counterflow Gravity
Condensate Return systems shown on page 7 are the pre­ferred systems. These systems are merely two examples of
many possible systems. Determination of the proper system
is based upon the application and is therefore beyond the
scope of this instruction.

2. The 18" minimum height shown in figures 1-3, is the mini­mum height between the top of the jacket of the boiler and
the 2-1/2" x 12" header centerline in the supply piping from
the boiler. It must NOT be confused with the minimum
height between the water level and the lowest return bend of
the steam supply main. This height is "H" as shown in fig­ures 2 and 3.
The minimum height of "H" must be at least equal to the
sum of the pressure drop of the system plus three times the
friction loss of the wet return, but not less than 18" for a sys­tem with a 1/8" psi steam pressure drop and not less than
28" for a system with a 1/2" psi steam pressure drop.

3. Modern steam boilers are smaller in water content than the
boilers that they replace, therefore a mechanical return sys­tem (pump, receiver, etc.) must be employed if conditions
exist such that uniform condensate return flow to the boiler
cannot be maintained.
Pocketing of condensate and the inability to maintain the
correct minimum height between the steam supply main and
the water level in the boiler are but a few of the many condi­tions that indicate the use of a mechanical return system.
Any use of a receiver and pump must be coordinated with
the makeup water and controlled by the boiler water level
control on the boiler. This description is typical of a boiler
feed pump as opposed to a condensate pump that pumps
condensate regardless of the water level in the boiler.

4. In any steam system one of the requirements is the removal
of air from the system. A mechanical return system in most
cases has an air vent on the receiver. A gravity return sys­tem has no receiver, so provisions for air removal must be
made on the piping itself. A one pipe system has the air
vents on the radiation, the heat exchanger and near the end
of the steam supply main (see figures 2 and 3).
Main air vents should be located fifteen inches from the drip
and if possible eight inches above the pipe so that water
hammer does not damage the vent and render the vent
inoperable.
For more information on air vents, check with any manufac­turer of steam accessories (steam traps, boiler feed pumps,
air vents, etc.).

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, on
page 4.

INSTALLATION INSTRUCTIONS FOR GXH OR GXHA LOW
PRESSURE STEAM BOILERS EQUIPPED WITH TANKLESS
OR PROVISION FOR TANKLESS AND McDONNELL &
MILLER TYPE 67 LOW WATER CUT-OFF.
STEAM CONTROLS ASSEMBLY AND INSTALLATION
INSTRUCTIONS

Steam kit components for Galaxy packaged models are packed
as follows:
A. 1.Low water cut-off control

2. Fittings

3. L.W.C.O. instruction sheet

B. 1.Pressure gauge

2. High pressure limit control

3. Water level gauge

4. Fittings

5. Instruction sheet and assembly drawing

6. Steam safety valve and 3/4" street coupling

7. Drain cock

Assemble above components exactly as shown in steam con­trols assembly. Two 1/2" tappings are on right side of boiler for
this assembly. Two holes are pre-punched in jackets. For con­venience, start assembling in the following steps:

1. Install 1/2" x 5-1/2" brass nipple onto tee of L.W.C.O.

2. Mount 1/2" x 5-1/2" brass nipple into lower boiler tapping by
rotating low water cut-off.

3. Assemble 90° brass tubing to tee adapter and L.W.C.O.

4. Install 1/2" x 6" brass nipple and 1/2" x 5/8" adapter tee in
upper boiler tapping.

5. Install syphon, high pressure limit and pressure gauge with
1/4" brass fittings.

6. Install water level gauge (without glass) and its fittings.

7. Install water level glass, and mark the glass 25-1/2" from the
bottom of the steel boiler base for the water level. (The
steel boiler base should not be confused with a combustible
floor kit when making the 25-1/2" measurement.)

8. Drain cock will be installed in return tee at the lower right
side of casting.

9. Safety valve and 3/4" street coupling should be installed in
3/4" tapping on top of boiler.