GA100CS Series
Combination Gas
Fired Cast Iron
Boiler and Indirect
Water Heater
Vaillant ......
Installation and
Service Manual
Table of Contents
Page
Number
2
1. Boiler Dimensions
& Specifications
2. Rules for Safe Installation 3
& Operation
3. Locating the Unit 3
4. Combustion Air Requirements 3
5. Vent Pipe Connections 4
6. System Piping Boiler 5
7. Gas Supply Piping 5
8. Electrical Wiring 7
9. Flame Roll-Out 7
10. Blocked Vent System 9
11, Checkout Procedures 9
12. Maintenance Requirements 10
®
PRICE $5.00
Vaillant
Vaillant Corp.
2607 River Road
Cinnaminson, NJ 08077
(609) 786-2000
Fax (609) 786-8465
All of our appliances should be installed
by qualified fitters only, who will be
responsible for the observance of all
existing national and/or local installation
inStructionsand code regulations.
On installation please hand this pamphlet
to your customer.
o)
T--
"T
o
z
1. Boiler Dimensions & Specifications
I*-- 3o'/,"--÷1
SideView
Fig. 1 - GA100 CS Series Boiler
,-8
-IBI--
.=
t"------" 221/4" --'-*1
FrontView
with Door Off
[__._]A ---*
i°
16
t
RearView
ModM A B
" GAt00CS-6 10_/1" 5"
GAI00CS_ 11_11" 5"
GAI00CS-10 12_4" 6'
]
1. High Limit Control (Tank)
2. Combination Control
3. Transformer Relay
4. Intermittent Ignition Control
5. Combination Pressure Temp. Gauge
6. Damper Actuator
7. Combination Gas Valve
8. Circulator
9. Wet Leg Drain Tappings
10. Pilot Inspection Door
11. Tank Inspection Plate
12. Water Storage Tank
13. Temperature Sensor Well
14. Air Scoop
15. Vent Valve
16. DivertingValve
17. Expansion Tank
18. Boiler drain _' NPT
19. Return 1" NPT
20. Supply 1" NPT
21. Domestic Water Out (Hot) ¾"
22. Domestic Water In (Cold) ¾"
23. Gas line ½" NPT
24. Draft Diverter
25. 30 PSI A.S.M.E. Relief Valve
26. Tank Drain
27.125 PSI A.S.M.E. T&P Relief Valve
BOILER " " "- HEATING I-B-R NET
INPUT WBGHT
MODEL BTU/HR CAPACITY RATING I.BS.
NO. BTU/HR B'I'U/HR
GA100CS -6 60,000 ,50,000 43,000 340
GA100CS -8 80,000 67,000 58,000 360
GA100CS -10 100,000 85,000 74,000 390
2. Rules for Safe
Installation &
Operation
1. Read this manual and the
Owner's Manual carefully.
Failure to follow the rules for
safe operation and the instruc-
tions could cause a malfunction
of the boiler and result in death,
serious injury, and/or property
damage.
2. Check your local codes and
utility requirements before
installation. The installation
must be in accordance with
their directives.
3. Before servicing, allow boiler to
cool and always shut off any
electricity and gas to boiler
when working on it. This will
prevent any electrical shocks or
burns.
4. Never test for leaks with open
flame. Use soap suds to check
all connections. This will avoid
any possibilityof fire or explo-
sion.
5. Be certain boiler isequipped for
type of gas (natural or propane)
to be used. Over-firing will result
in premature failure of the boiler
sections and cause dangerous
operation.
6. Never vent this boiler into an
enclosed space. Always con-
nect the boiler to the outside.
Never vent to another room or
inside a building.
7. Be sure there is adequate air
supply for complete combus-
tion.
8. Follow a regular service and
maintenance schedule for effi-
cient and safe operation.
WHEN YOUR BOILER ARRIVES
BE SURE TO SAVE AND REFER
TO INSTRUCTION .S_"-
First, inspect each item received for
visible damage or shortage. If any
parts are damaged, report this to
the freight company immediately,
and request them to cell and make
an inspection before you make any
installation. Have the Inspector
prepare a signed report. Send
Vaillant a copy of this report and we
will send replacements for the
damaged parts. But, we must have
the signed inspection report ofthe
freight company to prove their
liability.
Examine all packaging material
carefully for loose parts before
discarding.
Also, store all parts received where
they will not be lost or damaged.
If you have had to unpack the boiler
outside, you may also have to dis-
assemble itto carry itto the installa-
tion area. In this case, use the Parts
List drawings hereinto guide you.
NOTE: The GA1 O0CS Series of
boilers were evaluated by the
American Gas Association to certify
that they meet all of the safety crite-
ria of ANSI standard 7_21.13a-Latest
Edition "Gas Fired Low Pressure
Steam and Hot Water Boilers." Safe
lightingand other performance crite-
ria were met with the gas manifold
and control assembly provided on
the boiler when the boiler underwent
tests specified in this standard.
The following steps are all neces-
sary for proper installation and safe
operation of the boiler.
1. Locating the boiler.
2. Fresh air for combustion.
3. Chimney & vent pipe connection.
4. System piping.
5. Gas supply piping.
6. Electrical wiring.
7. Check out and adjust.
8. Maintenance.
3, Locating the Unit
If unit is to be part of an existing
system, it is usually best to put it
where the old one was. If you plan
to change location, you will need
additional material as well as an
adequate base. The following rules
apply not only to replacement boil-
ers, they also applyto new installa-
tions:
1. The unit must be level.
2. Use a raised base if floor can
become wet or damp.
3. The vent pipe connection should
be short. The center ofthe chim-
ney opening must be high
enough to allow a '/,"per ft.
upward slope in vent from unit
to chimney opening
4. Maintain clearances for fire safety
as well as servicing.
The room must have a total cubic
foot volume notless than 16
times that of the boiler.
5. Fresh air for combustionmust be
available at the front ofthe boiler.
6. While this boiler may be installed
on combustibleflooring, it must
not be installed on carpeting.
7. The installation mustconform to
the requirements of the authority
having jurisdictionor, in the
absence of such requirements, to
the national Fuel Gas Code.
ANSI Z223.1-Latest Edition.
8. 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-I.
Clearance from Combustible
Materials
The following minimumclearances
are required between boiler and
combustible construction:
Top ............................... 12 inches
Right Side....................... 6 inches
Left Side ......................... 6 inches
Rear................................ 6 inches
Flue Connector ............... 6 inches
Hot Water Pipe ................... 1 inch
Flue and stackmust be at least 6"
from combustible surfaces.
If hotwater pipe passes through
combustible floors,walls, or ceil-
ings, clearance must be not less
than ½"capped with a non-com-
bustible plate (see NFPA bulletin
89M, heating equipment clearance).
Servicing requirements may require
larger clearances than those
required forfire safety.
As the electrical and piping connec-
tions are at the rear of the unit,
there should be space to permit
access to the rear of the unit for ser-
vice.
4. Combustion Air
Requirements
WARNING
Be Sure to Provide Enough Fresh
Air for Combustion
You must providefor enough fresh
air to assure proper combustion.
The fire in the unit uses oxygen.
The air in a house contains only
enough oxygen to supply the bumer
for a short time. Outside air must
enter the house to replace that used
bythe burner. Study the following
examples to determine your fresh
air requirements.
EXAMPLE 1: UNIT LOCATION IN
UNCONFINED SPACE
Ifyour unit is in an open area in a
conventional house, the air that
leaks through the cracks around the
door and windows will usually be
adequate to provide air for combus-
tion. The doors should notfit tightly.
Do not caulk the cracks around the
windows.
EXAMPLE 2: UNIT LOCATED IN A
HOUSE HAVING TIGHT CON-
STRUCTION
If the house is of tight construction
with weathemtripped windows, not
enough outside air will enter for safe
combustion. Installa duct orpipe
from a point near the burner to a
ventilated attic or crawl space orthe
outside where fresh air is freely
available. Vertical ducts should
have a net free area of 1 square
inchfor each 4,000 BTU per hour
input of all gas appliances and for
each 2,000 BTUihr. if horizontal
ducts are used. Screen the open-
ings to keep animals and birdsfrom
entering. This is also required ifthe
boiler is installed near an exhaust
fan orclothes dryer.
Provisions for combustion and venti-
lation air in accordance with section
5.3, Air for CombustTon'_nd
Ventilation, of the National Fuel Gas
Cede, ANSI Z223.1-Latest Edition,
or applicable provisions of the local
building codes.
5. Vent Pipe
Connections
Check Your Chlmney
This is a very important part of your
heating system. It must be clean,
the dght size, propedy con_ed
and in good condition. No boiler can
function properly with a bad chim-
ney. If your chimney isjust big
enough for your new boiler, it will
not have extra capacity forother
gas appliances.
When two or more appliances are
vented into the same chimney, the
cress-section area inside the chim-
ney must be at least equal to the
area ofthe largest vent PLUS ½the
area of each additional vent.
For example, if your boiler vent has
a diameter of 5 inches (area 19.6
square inches), the water heater
vent, a diameter of 4 inches (12.6
square inches), the minimum chim-
ney area must be 19.6+ ½ of 12.6 or
25.9 square inches. They will
require a 6" diameter round chim-
ney.
When removing a boiler from a
common venting system the venting
system is likely to be too large:for
proper venting of the remaining
appliances connected to it.
At the time of removal of an existing
boiler, the following steps shall be
followed with each appliance
remaining connected to the com-
mon venting system placed in oper-
ation, while the other appliances
remaining connected to the com-
mon venting system are not in oper-
ation.
(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
isno blockage or restriction, leak-
age, corrosion and other deficien-
cies which could cause an unsafe
condition.
(c) Insofar as is practical, close
all buildingdoors 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 dryer and any appliance
not connected to the common
venting system. Turn on any
exhaust fans, such as range
hoods and bathroom exhausts,
4
so they will operate at maximum
speed. Do not operate a summer
exhaust fan.
(d) Place in operationthe appli-
ance being inspected. Followthe
lighting instructions.Adjust ther-
mostat so appliance will operate
continuously.
(e) Test for spillage at the draft
hoed relief opening after 5 min-
utes of main burner operation.
Use the flame of a match or can-
dle, or smoke from a cigarette,
cigar or pipe.
(f) After it has been determined
that each appliance remaining
connected to the common vent-
ing system propedy vents when
tested as outlined above, return
doors, windows, exhaust fans,
fireplace dampers and any other
gas burning appliance to their
previous conditionsof use.
(g) Any improperoperation 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 por-
tion of the common venting sys-
tem, 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 Z223.1-Latest
Edition
Connect the Vent Pipe
WARNING
NEVERINSTALLA MANUALLY
OPERATED DAMPER IN THE
VENT PIPE OFANY GAS APPLI-
ANCE.
1. Do not modify draft diverter fur-
nished with the boiler.
2. Vent pipe must be same size as
outlet collar on draft diverter.
3. Slope pipe up from b_ler'to chim-
ney not less than ¼"per foot.
4. Run pipe as directly as possible
with as few elbows as possible.
5. Do notconnect to fireplace flue.
6. The sections ofvent pipeshould
be fastened with sheet metal screws
to make the piping rigid. Use
stovepipe wires to support the pipe
from above.
Loading...