Milwaukee GSA-075 User manual
Part Number 550-110-738/1012
G SA
Gas-Fired Steam Boilers
Boiler Manual
This manual must only be used by a qualified heating installer/service technician. Failure to comply could result in
severe personal injury, death or substantial property damage.
When calling or writing about the boiler— Please have: •boiler model number from the boiler rating label and
•CPnumberfromtheboilerjacket.YoumaylisttheCPnumberinthespaceprovidedonthe“Installationandservice
certicate”foundonpage20.
Contents Page
1 Prepare boiler location .......................................................2
2 Prepare boiler.....................................................................8
3 Installpiping .....................................................................11
4 Installcontrols ..................................................................14
5 Installgaspiping...............................................................15
6 Field Wiring ......................................................................16
7 Start-up ............................................................................ 17
8 Checkoutprocedure .........................................................20
9 Service and maintenance.................................................21
10 Replacement parts ........................................................... 26
11 Dimensions....................................................................... 30
12 Ratings ............................................................................. 31
For Operating and Troubleshooting Instructions,
see Spark Ignition Control Supplement
Hazards that will or can cause minor personal
injury or property damage.
Special instructions on installation, operation or
maintenance that are important but not related to
personal injury or property damage.
INSTALLER —Readallinstructionsbeforeinstall-
ing. Read page 2 first. Follow all instructions in
proper order to prevent personal injury or death.
• Considerpipingandinstallationwhendetermining
boiler location.
• Anyclaimsfor damageorshortage in shipment
must be filed immediately against the transporta-
tion company by the consignee.
• GSAboilerscannotbeadaptedforheateruse.
Hazards that will cause severe personal injury,
death or substantial property damage.
Hazards that can cause severe personal injury,
death or substantial property damage.
Hazard definitions
USER — Please read the following. Failure to
comply could result in severe personal injury,
death or substantial property damage.
• This document is for use only by your qualified
heating installer/service technician.
• PleaseseetheUser’sInformationManualforyour
reference.
• Have the boiler serviced by a qualied service
technician, at least annually.
INSTALLER —
Spark ignition boilers — Refertothismanual
forgeneralinstallationandmaintenanceinforma-
tion.ReferalsototheGSASparkIgnitionControl
Supplement,partnumber550‑141‑971,foroperat-
ing instructions, troubleshooting and other additional
information for GSA boilers equipped with spark
ignition.
GSA
Gas-Fired Steam Boilers – Boiler Manual
2Part Number 550-110-738/1012
This manual must only be used by a qualified
heating installer/service technician. Read
theseinstructionscompletelybeforebeginningthe
installation.Failuretofollowtheseinstructionscan
cause severe personal injury, death or substantial
property damage.
Improper installation, adjustment, alteration, service or
maintenance can cause property damage, personal injury,
exposuretohazardousmaterials,orlossoflife.Refertothe
User’sInformationManualprovidedwiththisboiler.Installation
andservicemustbeperformedbyaqualiedinstaller,service
agencyorthegassupplierwhomustreadandfollowthe
suppliedinstructionsbeforeinstalling,servicingorremovingthis
boiler. This boiler contains materials that have been identified
as carcinogenic, or possibly carcinogenic, to humans.
Failure to adhere to the guidelines below
can result in severe personal injury, death or
substantial property damage.
The boiler contains ceramic fiber and fiberglass
materials.Usecarewhenhandlingthese
materials per instructions on page 25 of this
manual. Failure to comply could result in severe
personal injury.
When servicing boiler —
1. Toavoidelectricshock,disconnectelectricalsupplybefore
performingmaintenance.
2. Toavoidsevereburns,allowboilertocoolbeforeperforming
maintenance.
Boiler operation —
3. Donotblockowofcombustionorventilationairtoboiler.
4. Shouldoverheatingoccur,turnoffordisconnectelectrical
supplytoboilerandshutoffthegassupplyatalocation
externaltotheappliance,ifpossible.
5. Donotusethisboilerifanyparthasbeenunderwater.
Immediatelycallaqualiedservicetechniciantoinspectthe
boilerandtoreplaceanypartofthecontrolsystemandany
gas control that has been under water.
Boiler water —
6. DO NOT use petroleum-based cleaning or sealing
compounds in boiler system. Water seal deterioration will
occur,causingleakagebetweenboilersections,circulator
anges,diaphragmtanksorothersystemcomponents.This
can result in substantial property damage.
7. DONOTuse“homemadecures”or“boilerpatent
medicines”. Serious damage to boiler, personnel and/or
property may result.
8. Continualfreshmakeupwaterwillreduceboilerlife.Mineral
buildupinsectionsreducesheattransfer,overheatscast
iron, and causes section failure. Addition of oxygen and
othergasescancauseinternalcorrosion.Leaksinboileror
pipingmustberepairedatoncetopreventmakeupwater.
9. Donotaddcoldwatertohotboiler.Thermalshockcancause
sectionstocrack.
1 Prepare boiler location
Codes & Checklist
Installations must follow these codes:
• Local,state,provincial,andnationalcodes,laws,regulations
and ordinances.
• NationalFuelGasCode,ANSIZ223.1–latestedition.
• StandardforControlsandSafetyDevicesforAutomatically
FiredBoilers,ANSI/ASMECSD‑1,whenrequired.
• NationalElectricalCode.
• ForCanadaonly:B149.1orB149.2InstallationCode,CSA
C22.1CanadianElectricalCodePart1andanylocalcodes.
Certification
TheGSAboilergasmanifoldandcontrolsmetsafe
Lightingandotherperformancecriteriawhenboiler
underwent tests specied in ANSI Z21.13–latest
edition.
Before locating the boiler:
o Checkfornearbyconnectionto:
• Ventingconnections
• Gassupplypiping
• Electricalpower
o Checkareaaroundboiler.Removeanycombustiblematerials,
gasolineandotherammableliquids.
Failuretokeepboilerareaclearandfreeofcom-
bustible materials, gasoline and other ammable
liquids and vapors can result in severe personal
injury, death or substantial property damage.
oBoiler must be installed so that gas control system components
areprotectedfromdrippingorsprayingwaterorrainduring
operation or service.
o Ifnewboilerwillreplaceexistingboiler,checkforandcorrect
system problems, such as:
• Systemleakscausingoxygencorrosionorsectioncracks
fromhardwaterdeposits.
Read this first!
GSA
Gas-Fired Steam Boilers – Boiler Manual
3
Part Number 550-110-738/1012
1 Prepare boiler location continued
Clearances
Recommended SERVICE clearances
1. Provideminimumclearancesforcleaningandservicingthe
boilerandforaccesstocontrolsandcomponentsaslistedin
the table at right.
2. Provideatleastscrewdriverclearancetojacketfrontpanel
screwsforremovaloffrontpanelforinspectionandminor
service.Ifunabletoprovideatleastscrewdriverclearance,
installunionsandshutoffvalvesinsystemsoboilercanbe
movedforservicing.
Figure 1 Alcove installations
Minimum clearances to COMBUSTIBLE
materials
General clearances — All installations
1. See the table atright for clearances to boiler and system
components.
2. ClearancestoTypeBventmaterialsareasspeciedbythe
ventmanufacturer.
Alcove (not closet) installations only
GSAboilersarenotapprovedforcloset installation
––onlyforalcoveinstallation,withminimum
clearancestocombustiblesurfacesasshowninthe
tableatright.SeeFigure1.Thefrontsidemustbe
completely open — that is, a 3-walled room.
Clearance for service Minimum
Clearance to boiler jacket
Top (for cleaning ueways) 46”
Front (for access to controls and components) 18”
Back 6”
Left side (for cleaning and servicing) 24”
Right side 6”
Clearance to combustible materials Minimum
Clearance to boiler jacket
Top 46”
Front (provides means of access) 3”
Back 6”
Left side (provides means of access) 4”
Right side 4”
Clearance to piping and vent components
Water and steam pipes 1/2”
Vent pipe (other than Type B vent) 6”
Type B vent piping Per B vent
manufacturer
Vent damper 6”
GSA
Gas-Fired Steam Boilers – Boiler Manual
4Part Number 550-110-738/1012
1 Prepare boiler location continued
Vent System
Failuretofollowallinstructionscanresultinuegas
spillage and carbon monoxide emissions, causing
severe personal injury or death.
Inspect existing chimney before installing boiler.
Failure to clean or replace perforated pipe or tile
lining will cause severe personal injury or death.
Donotalterboilerdrafthoodorplaceanyobstruc-
tion or non-certified vent damper in breeching or
vent system. CSA certication will become void.
Flue gas spillage and carbon monoxide emissions
will occur causing severe personal injury or death.
Thefollowingrequirementsapplywhenyouremove
anexistingboilerfromaventsystemsharedwith
other appliances. If the new boiler will not use the
common vent, you must test (as described below)
eachremainingappliance—operatingbyitself—to
verifythattheventsystemoperatesadequately.
When removing boiler from existing common vent
system:
Atthetimeofremovalofanexistingboiler,thefollowingsteps
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. Visuallyinspecttheventingsystemforpropersizeand
horizontalpitchanddeterminethereisnoblockageor
restriction,leakage,corrosionorotherdeciencieswhichcould
causeanunsafecondition.
c. Testventsystem—Insofarasispractical,closeallbuilding
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
commonventingsystem.Turnonanyexhaustfans,suchas
range hoods and bathroom exhausts, so they will operate at
maximumspeed.Donotoperateasummerexhaustfan.Close
fireplace dampers.
d. Place in operation the appliance being inspected. Follow the
operating instructions. Adjust thermostat so appliance will
operate continuously.
e. Testforspillageatdrafthoodreliefopeningafter5min-
utesofmainburneroperation.Usetheameofamatchor
candle.
f. Afterithasbeendeterminedthateachapplianceremaining
connected to the common venting system properly vents when
testedasoutlinedabove,returndoors,windows,exhaustfans,
fireplace dampers, and any other gas-burning appliance to
theirpreviousconditionsofuse.
Anyimproperoperationofthecommonventingsystemshouldbe
correctedsotheinstallationconformswiththeNationalFuelGas
Code,ANSIZ223.1/NFPA54and/orCAN/CGAB149,Installation
Codes.Whenresizinganyportionofthecommonventingsys-
tem, the common venting system should be resized to approach
the minimum size as determined using the appropriate tables
in the National Fuel Gas Code, ANSIZ223.1/NFPA54 and/or
CANCGAB149,InstallationCodes.
Residential garage installation
Takethefollowingspecialprecautionswheninstallingtheboilerin
aresidentialgarage.Iftheboilerislocatedinaresidentialgarage,
perANSIZ223.1:
• Mounttheboileraminimumof18inchesabovetheoorof
the garage to assure the burner and ignition devices will be
nolessthan18inchesabovetheoor.
• Locateorprotecttheboilersoitcannotbedamagedbya
moving vehicle.
Flooring and foundation
Donotinstallboileroncombustibleooringor
carpetingevenifaconcreteoraeratedfoundation
is used. Fire can result, causing severe personal
injury, death or substantial property damage.
1. Providea solidbrick orminimum2‑inch thickconcrete
foundationpadifanyofthefollowingistrue:
• oorcanbecomeooded.
• theboilermountingareaisnotlevel.
2. SeeTable1forminimumfoundationdimensions.
3. Useafoundationwithairwayswhen:
• Electricalwiringortelephonecablesburiedintheconcrete
ooroftheboilerroom.
• Concreteooris“green”.
• Waterischanneledundertheconcrete.
Boiler
model
Minimum
foundation
length
Minimum
foundation
“L” width
GSA-075 –– GSA-100 29 ⅝” 19”
GSA-125 –– GSA-150 29 ⅝” 23 ¼”
GSA-175 –– GSA-200 29 ⅝” 27 ½”
GSA-250 29 ⅝” 31 ¾”
GSA-300 29 ⅝” 36”
Table 1 Minimum foundation size
GSA
Gas-Fired Steam Boilers – Boiler Manual
5
Part Number 550-110-738/1012
Figure 2 Terminations with Type B vent fitted with
listed cap, provided vent is at least 8 feet from
any vertical wall or similar obstruction locations
1 Prepare boiler location continued
Air contamination
Pleasereviewthefollowinginformationonpotentialcombustion
air contamination problems.
SeeTable2forproductsandareaswhichmaycausecontaminated
combustion air.
To prevent potential of severe personal injury or
death, check for products or areas listed below
beforeinstallingboiler.Ifanyofthesecontaminants
arefound:
•Removecontaminantspermanently.
— OR —
•Isolateboilerandprovideoutsidecombustion
air.Seenational,provincialorlocalcodesfor
furtherinformation.
Table 2 Corrosive contaminants and likely locations
Vent System
Chimney or vent requirements
1. VentingmustbeinstalledaccordingtotheNationalFuelGas
Code, ANSI Z223.1–latest edition and applicable building
codes. Canadian installations must comply with B149.1 or
B149.2InstallationCodes.
2. See“Ratings”onpage31forminimumchimneyorventsizes.
Chimneyorventtermination:
• Achimney,oranyventotherthanaTypeBventwithlisted
ventcap,mustextendatleast3feetabovethehighest
pointwhereitpassesthrougharoofofabuilding,andat
least2feethigherthananyportionofabuildingwithina
horizontaldistanceof10feet.
• TypeBventswithlistedcapsmayterminateasinFigure2
ifnocloserthan8feetfromaverticalwallorsimilar
obstruction.
• Otherwise,Type B vents must terminate at least 2 feet
abovetheroofpenetrationandatleast2feethigherthan
anyportionofabuildingwithin10feet.
3. Alinedchimneyispreferredandmustbeusedwhenrequired
by local, state, provincial and national codes, laws, regulations
and ordinances.Vitreous tile linings with joints that prevent
retentionofmoistureandliningsmadeofnoncorrosive
materialsarebest.Adviceforueconnectionsandchimney
liningscanbeobtainedfromlocalgasutility.TypeBdouble‑
wall metal vent pipe or single-wall vent pipe may be used as
a liner.
4. Cold masonry chimneys, also known as outside chimneys,
typically have one or more walls exposed to outside air.
When any atmospheric gas-fired boiler with automatic vent
damperisventedthroughthistypeofchimney,thepotential
existsforcondensationtooccur.Condensationcandamagea
masonrychimney.Thefollowingarerecommendedtoprevent
possible damage.
a. Line chimney with corrosion-resistant metal liner such as
AL29‑4C®single‑wallstainlesssteelorB‑vent.Sizeliner
perNationalFuelGasCodeANSIZ223.1–latestedition.
b. Provide drain trap to remove any condensate.
5. Where two or more gas appliances vent into a common
chimneyorvent,equivalentareashouldbeatleastequalto
areaofventoutletonlargestapplianceplus50percentofvent
outletareaofadditionalappliances.
Products to avoid
Spray cans containing chloro/uorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents found in
household laundry rooms
Adhesives used to fasten building products and other similar
products
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture renishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
Buildings under construction (where air is contaminated with
particulates)
GSA
Gas-Fired Steam Boilers – Boiler Manual
6Part Number 550-110-738/1012
1 Prepare boiler location continued
Air openings
Place boiler/crate near position
1. Leave boiler in crate and on pallet until installation site is
ready.
2. Moveentirecrateandpalletnexttoselectedlocation.
3. Remove crate. Leave boiler on pallet.
4. Unboltboilerfrompallet.
5. Removeboilerfrompallet.
Provideadequatecombustionandventilationairto
assurepropercombustionandreducetheriskof
severe personal injury, death or substantial property
damage caused by ue gas spillage and carbon
monoxide emissions.
Combustionairandventilationopeningsmustcomplywith
theNationalFuelGasCode,ANSIZ223.1–latestedition,orap-
plicablelocalbuildingcodes.Canadianinstallationsmustcomply
withB149.1orB149.2InstallationCodes.
Air opening sizes in the following are given in free area (after
correctionforlouverobstruction).
Option 1 — Provide (2) openings:
Option 2 — Provide (1) opening:
Asinglecombustionairopeningcanbeused,provided:
• Theopeningmustcommencewithin12inchesofthe ceiling.
• Theboilermusthaveclearancesofatleast1inchfromboth
sidesandback,and6inchesfromthefront.
• The opening must connect directly to the outdoors or to a
space that communicates directly to the outdoors.
• Theaircanbeprovidedthroughadirectopeningorthrough
a horizontal or vertical duct.
• Thefreeareaoftheopeningmustbeatleastequaltothe
sumofallventconnectorsinthespace.
• Thefreeareaoftheopeningmustbeatleast1squareinch
per3000Btu/hrinputratingofallequipmentlocatedinthe
space.
Tight construction — Definition:
Tightconstructionmeans(perANSIZ223.1):
• Wallsandceilingsexposedtotheoutsideatmospherehave
acontinuouswatervaporretarderwitharatingof1permor
lesswithopeningsgasketed.AND
• Weather‑strippinghasbeenaddedonopenablewindowsand
doors.AND
• Caulking or sealants are applied to areas such as joints
aroundwindowsanddoorframes,betweensoleplatesand
oors, between wall‑ceiling joints, between wall panels, at
penetrations for plumbing, electrical, and gas lines, and in
other openings.
Tight construction requirements
Ifbuildingisoftightconstructionandairistakenfrominsidethe
building, provide two openings in building outside wall, one within
12inchesofceiling,theotherwithin12inchesoftheoor.Each
openingmusthave a minimum free area of 1 square inch per
1,000Btuhofallappliancesinthebuilding.
Exception
NO combustion air openings are needed when the boiler (and
other appliances) are installed in a space with a volume NO
LESSthan50cubicfeetper1,000Btuhofallinstalledappliances.
Sumthe total input ofall appliances in MBH(1,000’s of Btuh)
andmultiplythisnumbertimes50.BuildingmustnotbeofTight
construction (see above).
Example:Fortotalinputof100MBH(100,000Btuh),minimum
volumeis50x100=5,000cubicfeet.Ataceilingheightof8feet,
spacemusthaveatleast5,000÷8=625squarefeet(25feetx
25feet,forinstance).
Exhaust fans and air movers
The appliance space must never be under a negative pressure.
Always provide air openings sized not only to the dimensions
requiredfor thering rateofallappliances, butalsotohandle
theairmovementrateoftheexhaustfansorairmoversusingair
fromthebuildingorspace.
Motorized air dampers
Iftheairopeningsarettedwithmotorizeddampers,electrically
interlockthedamperto:
• Preventtheboilerfromringifthedamperisnotfullyopen.
• Shuttheboilerdownshouldthedampercloseduringboiler
operation.
Toaccomplishthisinterlock,wireanisolatedcontact(provingthe
damper open) in series with the thermostat input to the boiler.The
boilerwillnotstartifthisdamperisclosed,andwillshutdown
should damper close during operation.
Placement and setup
GSA
Gas-Fired Steam Boilers – Boiler Manual
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Part Number 550-110-738/1012
1 Prepare boiler location continued
Setup - continued
Inspect orifices and burners
1. Removefrontjacketdoor.Removebaseaccesspanel(see
Figure 20, item 14, page 26).
2. Checkforcorrectly‑sizedmanifoldorices.SeeTable3
for sizing. (The orice size is stamped on the orice spud
barrel.)
Correctly‑sized manifold orices must be used.
Failure to do so will result in severe personal injury,
death or substantial property damage.
3. Level and straighten burners.
Burners must be properly seated in slots in burner
restwiththeiropeningsfaceup.Mainburnerorices
mustinjectdowncenterofburner.Failuretoproperly
seat burners will result in severe personal injury,
death or substantial property damage.
4. Reinstall base access panel.
Do not operate boiler without access panel secured
in place. Failure to comply could cause momentary
amerolloutonignitionofmainame,resultingin
possible fire or personal injury hazard.
Table 3 Manifold orifice sizing
Pressure test
Perform hydrostatic pressure test
Pressure test boiler before attaching water or gas piping or
electrical supply.
Prepare boiler for test
1. Plug tappings or openings.
2. Donotusegaugesuppliedwithboilerforpressuretesting.
Installgaugewithappropriaterange.
Fill and pressure test
1. Fill boiler with water. Vent all air.Test boilers between 45‑
50 psi.
Donotleaveboilerunattended.Acoldwaterllcould
expand and cause excessive pressure resulting in
severe personal injury, death or substantial property
damage.
2. Checkforstablegaugepressureformorethan10minutes.
Visuallycheckforleaksifgaugepressuredrops.
Do not use petroleum based cleaning or sealing
compounds in boiler system. Severe damage to
boiler will result, causing substantial property
damage.
2. Retestboilerafterrepairingleaks.
3. Removeplugsfromanytappingsthatwillbeusedforcontrols
andaccessories.RefertoTable4andFigure3.
Float‑type low water cutoff — If eld installing a
oat‑typelowwatercutoff,itmustbepipedonlyto
the gauge glass tappings, items H, Figure 3. The
tappingsarespaced9”oncenter.Useonlyoat‑type
lowwatercutoffswithquick‑connecthookupsthat
willprovidealowwatercutoffpointnohigherthan
2”abovethecenterofthebottomtapping.Seepage
14,Figure16,foratypicalinstallation.
Pressure test - continued
Table 4 Control tapping
Figure 3 Control tapping locations
Drain and remove fittings
1. Drainboilerandrepairleaksiffound.
Leaksmustberepairedatonce.Failuretodoso
can damage boiler, resulting in substantial property
damage.
Location Natural gas
U.S. Sea level – 2,000 ft.
2.45 mm
over 2,000 ft.
(Note 1)
Canada Sea level – 2,000 ft.
2.45 mm
2,000 ft. - 4,500 ft.
2.30 mm
Note 1: For U.S. elevations above 2,000 feet, contact your local
supplier for details.
Location Size Description
C¾” Probe-typelow water cutoff
D¾” Drain
E¾” Relief valve
G¾” Plugged
H½” Gauge glass and/or optional
low water cutoff
J
(See Note) ⅜” Tricock tappings
L½” Siphon, pressure gauge, high
limit control
S1 ½” Skim tapping
Note: Available only on special request.
GSA
Gas-Fired Steam Boilers – Boiler Manual
8Part Number 550-110-738/1012
2 Prepare boiler continued
Installation of drawer assembly,
front base panels –
1. SeeFigure6.Fastenfrontbasepanel(6 Z\, inch high)
and rear base channel to section assembly. Seal with
boilercementalongtopofinsulationpanels.
2. Theburnerdrawerassemblyconsistsoftheburner
drawer, main burners, gas manifold, pilot burner,
etc.
3. CheckforproperoricesizingfromTable3,page7
inGSAboilermanual.
Proper orifices must be used. Failure to
do so will cause severe personal injury,
death or substantial property damage.
4. Place burners in the drawer assembly as shown in
Figures 7 and 8.
5. Slide the drawer assembly under the front base
panel and attach to the section assembly as shown
in Figure 9.
6. Level and straighten burners.
Burners must be properly seated in slots in
backburnersupportwithopeningsfacing
up.Gasoricesmustinjectdowncenter
ofburner.Failuretoproperlyseatburners
will result in severe personal injury, death
or substantial property damage.
7. Installrolloutthermalfuseelementwithwiretermi-
nalsfacinguponfrontaccesspanelas shownin
Figure10.WirepertheappropriateControlSupple-
ment.
Inspect burners – GSA 300 boiler
1. AllunitsexceptGSA‑300arefactory‑assembled,but
the burners and base panels should be inspected to
ensure they are in good condition.
2. Remove the access panel (Figure 10) and inspect
the burners per step 6 above. Replace the access
panel.
Installation of flue collector hood
(Factory installed on GSA boilers up to GSA-300)
SetuecollectorhoodonboilerasshowninFigure4.Useboiler
cementfurnishedtoprovidegas‑tightseal.
Failuretomaintaingas‑tightsealcancauseuegas
spillage and carbon monoxide emissions, resulting
in severe personal injury or death.
Figure 4 Flue collector hood
Installation of rear base panels
(Factory installed on GSA boilers up to GSA-300)
See Figure 5. Fasten rear base panel ( 7B\zn inch high) and rear
base channel to section assembly. Seal with boiler cement along
topofinsulationpanels.
Failuretomaintaingas‑tightsealcancauseuegas
spillage and carbon monoxide emissions, resulting
in severe personal injury or death.
Figure 5 Rear base panel and base channel
GSA
Gas-Fired Steam Boilers – Boiler Manual
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Part Number 550-110-738/1012
2 Prepare boiler continued
Draft hood & spill switch
Draft hood installation
1. Secure draft hood to ue collector hood with sheet metal
screws.SeeFigure20,items1and9,onpage26.Useboiler
cement to provide gas tight seal.
Failuretomaintaingas‑tightsealcancauseuegas
spillage and carbon monoxide emissions, resulting
in severe personal injury or death.
Donotalterboilerdrafthoodorplaceanyobstruction
or non-approved vent damper in breeching or vent
system.CSAcerticationwillbecomevoid.Fluegas
spillage and carbon monoxide emissions will occur
causing severe personal injury or death.
Screw 10–32 x 3/8”
Screw #6 x ½”
Boiler cement
Access panel
Rollout TFE
63904-GSA
GSA-300
P
Burner
Pilot burner
Pilot
Legend:
P
Figure 10 Access panel
Figure 9 Burner drawer installation
Figure 8 Burner and pilot burner location
Figure 7 Burner drawer assembly
Figure 6 Front base panel
Jacket installation (uptoGSA‑300)
1. Removetheproperknockoutdiscsfrompanelsasshown
in Table 4, page 7.
2. FollowJacketInstructionsinjacketcarton.
Spill switch installation
1. FastenspillswitchtodrafthoodasshowninFigure20,item
20, page 26.
2. SeewiringdiagraminGSASparkIgnitionControlSupple-
ment to connect wires.
GSA
Gas-Fired Steam Boilers – Boiler Manual
10 Part Number 550-110-738/1012
Vent damper
Damper blade
Seeventmanufacturer’sinstructionstoinstallplug(shippedwith
damper)indamperhole.Installplugwith3/8”diameterholein
vent damper hole.
1. Installventdamperasshowninventdampermanufacturer’s
instructions.Ventdampermustbeinstalledsothatitserves
only one boiler and so damper blade indicator is visible to the
user. See Figure 11.
2. Screwsorrivetsusedtosecuretheventdampertothedraft
hoodmustnotinterferewithrotationofthedamperblade.
3. Installdamper harness between damperactuator and
knockoutinjackettoppanel.Usestrainreliefconnectorsand
locknutstosecurebothendsofdamperharness.
Keepwiringharnessclearofallhotsurfaces.Wire
insulationcouldbedamaged,causingriskof
electrical short-circuit.
4. Read and apply the harness plug warning label (shown above)
sothatitisvisibleafterinstallation
Damper installation
Figure 11 Vent damper assemblies
These systems are used on gas-fired boilers with
ventdampersasshippedfromfactory.Boilerwillnot
operate without vent damper installed.
Minimum clearances
Provide a minimum of 6” between the vent damper and any
combustiblematerial.(See“Minimumclearancetocombustible
materials,”page3,forminimumclearancefromjackettopto
ceiling to maintain this dimension.).
Donotmodifydrafthoodorventdamper,ormake
another connection between draft hood and vent
damper or boiler except as noted below. This will
voidCSAcertication and will not be covered by
warranty.Anychangeswillcauseseverepersonal
injury, death or substantial property damage.
2 Prepare boiler continued
5. Plug damper harness receptacle into damper harness plug.
Bypassing(jumpering)ventdamperwillcauseue
products such as carbon monoxide to escape into
the house.This will cause severe personal injury or
death.
Afterboilerhasoperatedonce,ifeitherendofhar-
nessisdisconnected,thesystemsafetyshutdown
will occur. The boiler will not operate until harness
is reconnected.
Efkal or Field Control dampers — Damper hold
openswitchmustbeinAutomaticOperationposition
forsystemtooperateproperly.
Install vent piping
1. Connectfromdrafthoodorventdamperoutlettochimneyor
vent with same size vent connector.
2. Wherepossible,verticalventingtotheoutsidefromthedraft
hoodorventdamperoutletwillofferbestperformance.
3. Where horizontal vent connector is used, slope upward at
least¼”perlinealfoottowardchimneyorventandsupport
with hangers to prevent sagging.
4. Breechingmustnotbeconnectedtoanyportionofa
mechanicaldraftsystemthatcanoperateunderpositive
pressure.
Long horizontal vent connector, excessive number
ofelbowortees,orotherobstructionsthatrestrict
theowofcombustion gases should be avoided.
Severe personal injury, death or substantial property
damage could result.
GSA
Gas-Fired Steam Boilers – Boiler Manual
11
Part Number 550-110-738/1012
3 Install piping
General
1. Pipe before installing controls. Connect return piping after
jacketisattached.Connectsupplypipingbeforeorafterjacket
is attached.
Failure to properly pipe the boiler may result in
improper operation and damage to the boiler or
building.
2. See Figure 12 and Table 6. Pipe exactly as shown.
3. Satisfactoryoperationofa steam heating system depends
onadequatecondensatereturntoboilertomaintainasteady
waterlevel.Avoidaddingrawmakeupwater.Whereconden-
satereturnisnotadequate,refertorecommendationson
page 13.
Figure 12 Recommended piping, piping for parallel-flow
systems only.
(see Table 6 for recommended sizing)
Table 6 Recommended pipe sizing
Connecting to counterflow piping
ApplytherecommendedpipinginFigures12and14onlywhen
connectingtoaparallel‑owsystem.Whenconnectingtoa
counterowsystem,theboilersteamsupplymustconnectinto
thetopofthecounterowsystemheader,asshowninFigure13.
Figure 13 Connection to counterflow steam piping
(see Table 6 for recommended sizing)
Boiler model number Riser (A) Header (H)
see Note
Equalizer (J)
GSA-075 and GSA-100 2” 2” 1 ½”
GSA-125 through GSA-175 2 ½” 2 ½” 1 ½”
GSA-200, GSA-250 & GSA-300 3” 3” 1 ½”
Note: 24” minimum from waterline to bottom of header.
GSA
Gas-Fired Steam Boilers – Boiler Manual
12 Part Number 550-110-738/1012
3 Install piping continued
Relief valve
During operation, this valve may discharge
large amounts of steam and/or hot water.
Therefore,toreducethepotentialfor bodily
injury and property damage, a discharge line
MUSTbeinstalledthat:
• Isconnectedfromtheoutlettoasafepoint
ofdischargewithnointerveningvalve.
• Allows complete drainage of both the valve
and the discharge line.
• Is independently supported and securely
anchored so as to avoid applied stress as
possible.
• Terminates freely to atmosphere where any
discharge will be clearly visible and is at no
riskoffreezing.
• Is,overitsentirelength,ofapipesizeequal
toorgreaterthanthatofthevalveoutlet.
Useonlyschedule40metalpipefordischarge.
(Do not use schedule 80, extra strong or
double strong pipe or connections.) DO NOT
CAP, PLUG OR OTHERWISE OBSTRUCT
DISCHARGEPIPEOUTLET!Ifdischargeis
piped upward, a condensate drain must be
provided in the elbow below the vertical pipe
topreventcondensatefromreturningintothe
valve. Failure to comply with these instructions
willcauseadangeroussprayofhotwaterand
steam that would cause severe personal injury
or death.
Table 7 Reservoir pipe sizing
Table 8 Boiler feed system sizing
Follow the steps below to avoid potential
severe personal injury, death or substantial
property damage.
• Wheninstallingthereliefvalve,ensurethat
all connections, including the valve inlet, are
cleanandfreefromanyforeignmatter.
• Mount the relief valve only in the vertical
position, directly connected to the tapping
designatedinthemanualontopoftheboiler.
• Use pipe compound sparingly, or tape, on
external threads only.
• Donotuseapipewrench!Usepropertype
and size wrench on wrench pads only.
Installreliefvalveintappingontopofboiler.SeeTable4,
page7,forcontroltappinglocations.Seethetagattached
tothereliefvalveformanufacturer’sinstructions.
Boiler
model
number
AHRI
gross
output
(pounds
steam
per hour)
Con-
densate
(gallons
per hour)
Minimum condenste receiver
capacity gallons for boiler
steaming times (minutes) of:
(note 1)
Sugguested
feed pump
capacity
(GPM @
15 PSI)
(note 2)
15 min. 30 min. 45 min. 60 min.
GSA-075 63 8 2 4 6 8 0.2
GSA-100 81 10 3 6 9 12 0.3
GSA-125 102 12 4 7 11 14 0.4
GSA-150 122 15 5 9 14 18 0.5
GSA-175 142 17 5 10 15 20 0.6
GSA-200 163 20 6 12 18 24 0.7
GSA-250 203 24 7 14 22 29 0.8
GSA-300 240 29 9 17 26 36 1.0
NOTES:
1. Maximum time to when condensate returns to boiler.
2. If pump capacity exceeds capacity shown, pump can be throttled with globe or
ball valve.
Boiler
model
number
Max. boiler
gross
output
Time from intial steaming to average condensate return
(boiler steaming capacity based on 970 Btu per pound of steam)
15 minutes 20 minutes 30 minutes
MBH gallons
pipe
length
(feet)
gallons
pipe
length
(feet)
gallons
pipe
length
(feet)
GSA-075/100 75 ¾ ¾1 ½1 ½32 ½
GSA-125/150 125 1 ¼ 1 ¼ 2 ½2 ¼ Use boiler feed
system
GSA-175 150 1 ½1 ½32 ½
GSA-200 175 1 ¾ 1 ¾
Use boiler feed
system
GSA-250 225 2 ½2
GSA-300 250 2 ½2 ¼
Designed full capacity steaming time of modern boilers is 10 minutes.
GSA
Gas-Fired Steam Boilers – Boiler Manual
13
Part Number 550-110-738/1012
3 Install piping continued
Condensate return
Modernsteamboilersaredesignedtosteamforlesstimethan
older, larger boilers. When replacing an older steam boiler the
system condensate return time may be longer than the steaming
time.Thiscouldcausethefollowingproblems:
1. Boilersttedwithanautomaticwaterfeedcouldoverll.
2. Unitsttedwithonlyalowwatercutoffwouldshutdownand
cyclewhilewaitingforcondensatetoreturn.
Followingisasimplemethodfordeterminingwhetherornota
reservoirpipeisrequiredtolengthensteamingtimefora
residential installation:
1. Disconnect condensate return line at existing boiler.
2. Heat
boilerandallowtosteamfor10minutes.Turnoff boiler.
3. Measurelengthoftimefromwhenboilerstartedtosteamto
when condensate begins to return through condensate line.
4. Measurelengthoftimefromwhencondensatebeginstoreturn
to when it stops returning. Divide this time by 2.
5. Addtimemeasuredinstep3totimecalculatedinstep4.This
sumistheaveragetimerequiredforcondensatetoreturnto
the boiler.
6. If this total time is 10 minutes or less, no reservoir pipe is
needed.
If total time for condensate to return to boiler (from step 5) is
morethan10minutes,areservoirpipe(orboilerfeedsystem)
isrecommended.SeeTable7,page12,forsuggestedreservoir
pipesize.InstallasshowninFigure14.
Forlargersystems(asnotedinTable7),useaboilerfeedsystem
withacondensatetankandfeedpump.Youwillhavetoinstalla
lowwatercutoff/pumpcontrolontheboilertooperatethepump.
UseTable8tosizeboilerfeedsystems.Seepage7,Table4,for
tappinglocations.(Theuseofacombinationcondensatetankand
oat‑controlledcondensatereturnpumpisnotrecommended.)
For most residential installations a reservoir pipe may be all that
is necessary to ensure proper operation.
Figure 14 Recommended piping for parallel-flow systems with
optional reservoir pipe
GSA
Gas-Fired Steam Boilers – Boiler Manual
14 Part Number 550-110-738/1012
4 Install controls
Controls
Failure to properly install, pipe and wire boiler
controls may result in severe damage to the boiler,
building and personnel.
1. ControlsaremountedandwiredasshowninFigure15.for
actual tapping locations see Table 4 and Figure 3 on
page 7.
2. Bringsupplywiringtoboiler.Mustbe14gaugeorheavier.
3. SeewiringdiagramintheGSASparkIgnitionControlSupple-
ment.
Figure 15 Controls
Float-type low water cutoff (when provided by others)
1. InstalllowwatercutoffasshowninFigure16,below.SeeTable
4andFigure3onpage7foractualtappinglocation.
2. Installblowdownlineinbottomofcutoff.Seecontrol
manufacturer’sinstructionsfordetails.
Pipeblowdownline nearoorclose tooordrain
toeliminatepotentialofsevereburns.Donotplug,
valve or place any obstruction in blowdown line.
3. Waterfeedersarenotrecommendedforprimarycontrol.A
lowwatercutoffwithpumpcontrollerisrecommendedwitha
condensatereceiverandfeedpump.
Figure 16 Float-type low water cutoff
(when provided by others)
GSA
Gas-Fired Steam Boilers – Boiler Manual
15
Part Number 550-110-738/1012
5 Install gas piping
Connecting gas supply piping to boiler
1. RemovejacketfrontpanelandseeFigure17topipegasto
boiler.
a. Installdriplegatinletofgasconnectiontoboiler.Where
localutilityrequiresdriplegtobeextendedtotheoor,
useappropriatelengthofnipplebetweencapandtee.
b. Installgroundjointunionforservicing,whenrequired.
c. Installmanualshutoffvalveingassupplypipingoutside
boilerjacketwhenrequiredbylocalcodesorutility
requirements.
d. InCanada—Whenusingmanualmainshutoffvalve,it
must be identified by the installer.
2. Support
piping with hangers, not by boiler or its accessories.
3. Purgeallairfromgassupplypiping.
4. Beforeplacingboilerinoperation,checkboileranditsgas
connectionforleaks.
a. Close manual main shutoff valve during any pressure
testing at less than 13” w.c.
b. Disconnectboilerandgasvalvefromgassupplypiping
during any pressure testing greater than 13” w.c.
Donotcheckforgasleakswithanopename—Use
bubbletest.Failuretousebubbletestorcheckfor
gasleakscancauseseverepersonalinjury,death
or substantial property damage.
5. Usepipedopecompatiblewithpropanegases.Applysparingly
onlytomalethreadsofpipejointssothatpipedopedoesnot
blockgasow.
Failure to apply pipe dope as described in this
manual can result in severe personal injury, death
or substantial property damage.
Table 9 Pipe capacity for 0.60 specific gravity natural gas
Natural Gas:
1. SeeTable9forpipelengthanddiameter. Base on rated
boiler input,foundonpage31(divideby1,000toobtaincubic
feet per hour). Table9 is only for gas with specic gravity
0.60,withapressuredropthroughthegaspipingof0.30”w.c.
Foradditionalgaspipesizinginformation,seeANSIZ223.1
(B149.1orB149.2forCanadianinstallations).
2. Inletpressurerequiredatgasvalveinlet:
• Maximum:13”w.c.
• Minimum:5”w.c.
• Manifoldgaspressure:3.5”w.c.
3. Install100%lockupgaspressureregulatorinsupplylineif
inletpressureexceeds13”w.c.Adjustfor13”w.c.maximum.
Propane Gas:
1. Contactgassuppliertosizepipes,tanksand100%lockup
gas pressure regulator.
2. Adjustpropanesupplyregulatorprovidedbygassupplierfor
13” w.c. maximum pressure.
3. Inletpressurerequiredatgasvalveinlet:
• Maximum:13”w.c.
• Minimum:11”w.c.
• Manifoldgaspressure:10”w.c.
Figure 17 Gas supply piping
Gas
pipe
length
(feet)
Capacity of pipe for pipe size of:
(Capacity in cubic feet gas per hour)
½” ¾” 1” 1¼” 1½” 2”
10 132 278 520 1050 1600 3050
20 92 190 350 730 1100 2100
30 73 152 285 590 860 1650
40 63 130 245 500 760 1450
50 56 115 215 440 670 1270
75 45 93 175 360 545 1020
100 38 79 150 305 460 870
150 31 64 120 250 380 710
GSA
Gas-Fired Steam Boilers – Boiler Manual
16 Part Number 550-110-738/1012
6 Field wiring
Foryoursafety,turnoffelectricalpowersupplyat
serviceentrancepanelbeforemakinganyelectrical
connectionstoavoidpossibleelectricshockhazard.
Failure to do so can cause severe personal injury
or death.
WiringmustbeN.E.C.Class1.
Ifrollout thermal fuse element wire supplied with
boiler must be replaced, type 200 °C wire or
equivalent must be used. If other original wiring
supplied with boiler must be replaced, use only type
105°Cwireorequivalent.
Boiler must be electrically grounded as required
byNationalElectricalCodeANSI/NFPA70–latest
edition.
Electrical installation must comply with:
1. NationalElectricalCodeandanyothernational,state,
provincial or local codes or regulations.
2. InCanada,CSAC22.1CanadianElectricalCode,andany
local codes.
Wiring connections
Boiler is shipped with controls completely wired, except spill switch
andventdamper.SeewiringdiagramintheGSASparkIgnition
ControlSupplement.
Thermostat
1. Connectthermostatasshownonwiringdiagramonboiler.
2. Installoninsidewallawayfrominuencesofdrafts,hotor
cold water pipes, lighting fixtures, television, sunrays or
fireplaces.
3. Ifthermostathasaheatanticipator,setheatanticipatorin
thermostattomatchpowerrequirementsofequipment
connected to it. See boiler wiring diagram (on boiler, or in
SparkIgntionControlSupplement)forrecommendedsetting.
Forotherdevices,seemanufacturer’sspecications.Wiring
diagramonboilergivessettingforcontrolmoduleandgas
valve.Alsoseeinstructionswiththermostat.
Junction box
Connect120VACpowerwiring(Figure18).Aseparateelectrical
circuitwithafuseddisconnectswitch(15amp.recommended)
shouldbeusedfortheboiler.
Figure 18 Field wiring connections — service switch and thermostat (or end switch) provided by installer
GSA
Gas-Fired Steam Boilers – Boiler Manual
17
Part Number 550-110-738/1012
7 Start-up
Preparation
Check for gas leaks
Before starting the boiler, and during initial opera-
tion,smellneartheoorandaroundtheboilerfor
gas odorant or any unusual odor. Do not proceed
withstart‑upifthereisanyindicationofagasleak.
Repairanyleakatonce.
Propaneboilersonly—Yourpropanesuppliermixes
anodorantwiththepropanetomakeitspresence
detectable.Insomeinstances,theodorantcanfade
and the gas may no longer have an odor.
• Propanegascanaccumulateatoorlevel.Smell
neartheoorforthegasodorantoranyunusual
odor.Ifyoususpectaleak,donotattempttolight
the pilot.
• Usecautionwhenattemptingtolightthepropane
pilot.Thisshouldbedonebyaqualiedser-
vicetechnician,particularlyifpilotoutagesare
common.
• Periodicallychecktheodorantlevelofyourgas.
• Inspectboilerandsystematleastyearlytomake
sureallgaspipingisleak‑tight.
• Consultyourpropanesupplierregardinginstallation
ofagasleakdetector.Therearesomeproductson
themarketintendedforthispurpose.Yoursupplier
may be able to suggest an appropriate device.
Determine if water treatment is needed
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Severe damage to
boiler will occur, resulting in substantial property
damage.
Eliminateallsystemleaks.Continualfreshmakeup
waterwillreduceboilerlife.Mineralscanbuildup
insections,reducingheattransfer,overheatingcast
iron,andcausingsectionfailure.
Consultlocalwatertreatmentcompaniesforunusuallyhardwater
areas (above 7 grains hardness) or low pH water conditions (below
7.0).BoilerwaterpHof7.0to8.5isrecommended.
Fill the system with water
1. Donotll(exceptforleakagetests)untilboilerisreadytobe
fired.
2. Filltonormalwaterline,halfwayupgaugeglass.
3. Boiler water pH 7.0 to 8.5 is recommended.
4. Followskimmingprocedure,right.
Skimming the boiler
Cleanallnewlyinstalledsteamboilerstoremove
oil and grease. Failure to properly clean can result
inviolentuctuationsofwaterlevel,waterpassing
into steam mains or high maintenance costs on
strainers, traps and vents.
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Severe damage to
boiler will occur, resulting in substantial property
damage.
1. Provide1½”pipingfromskimtappingtooordrain.
2. Adjustwaterlinetomidpointofskimtapping.SeeFigure3,
page 7.
3. Follow the appropriate Operating Instructions in the Spark
Ignition Control Supplement, to re the boiler to maintain
temperature below steaming rate.
4. Feedinwatertomaintainwaterlevel.Cycleburnerstoprevent
rise in steam pressure.
5. Continueskimminguntildischargeisclear.Maytakeseveral
hours.
6. Drain boiler.While boiler is warm, but not hot,ushallinterior
surfacesunderfullpressureuntildrainwaterrunsclear.
7. Removeskimpiping.Plugtapping.
8. Closedraincock.Fillwithfreshwatertowaterline.Start
burnersandsteamfor15minutestoremovedissolvedgases.
Stop burners.
9. Checktrapsandairventsforproperoperation.
10.Process may need to be repeated after several weeks of
operation.
Inspect base insulation
The boiler contains ceramic fiber and fiberglass
materials.Usecarewhenhandlingthesematerials
perinstructionsonpage25ofthismanual.Failure
to comply could result in severe personal injury.
Checktomakesureinsulationissecureagainstallfoursidesof
thebase.Ifinsulationisdamagedordisplaced,donotoperate
boiler. Replace or reposition insulation.
Failure to replace damaged insulation or reposition
insulation can result in a fire hazard, causing
severe personal injury, death or substantial property
damage.
GSA
Gas-Fired Steam Boilers – Boiler Manual
18 Part Number 550-110-738/1012
7 Start-up continued
Operate the boiler
Start the boiler
1. Checkboilerwaterlevel—Shouldbeapproximately½way
up gauge glass.
2. Removeboilerjacketdoorandnotethegasvalvemanufacturer
and model number.
3. FollowtheappropriateOperatingInstructionsfoundintheGSA
SparkIgnitionControlSupplement.(TheOperatingInstruction
labelontheboilerprovidesthesameinformation.)
3. Ifboilerfailstostart,see“Ifboilerdoesn’tstart...Checkfor:”
on this page.
Check system and boiler
Eliminateallsystemleaks.Continualfreshmakeup
waterwillreduceboilerlife.Mineralscanbuildup
insections,reducingheattransfer,overheatingcast
iron,andcausingsectionfailure.
Ifyoudiscoverevidenceofanygasleak,shutdown
theboileratonce.Findtheleaksourcewithbubble
test and repair immediately. Do not start boiler again
until corrected. Failure to comply could result in
severe personal injury, death or substantial property
damage.
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Severe damage to
boiler will occur, resulting in substantial property
damage.
1. Checksystempipingforleaks.Iffound,shutdownboilerand
repair immediately.
2. Inspectventsystemthoroughlyforsignsofdeteriorationfrom
corrosion,physicaldamageorsagging.Verifythatmasonry
chimney liners are in good condition, with no obstructions,
and there are no openings into the chimney.
3. Checkaroundtheboilerforgasodorfollowingtheprocedure
of“Checkforgasleaks”,page17.
4. Verifyoperationusingproceduresbelow.Perform“Checkout
procedure”,page20,andllinthe“Installationandservice
certificate”.
If boiler doesn’t start . . . Check for:
1. Looseconnections,blownfuseorserviceswitchoff?
2. Highlimitswitchsetbelowboilerpressure?
3. Thermostatsetbelowroomtemperature?
4. Gasnotturnedonatmeterorboiler?
5. Incominggaspressurelessthan:
5”w.c.fornaturalgas?11”w.c.forpropanegas?
6. Ifnoneoftheabovecorrectstheproblem,see“Troubleshoot-
ing”,intheGSASparkIgnitionControlSupplement.
DO NOT proceed with boiler operation unless
boiler and system have been filled with water
andallinstructionsandproceduresofprevious
manual sections have been completed. Failure to
do so could result in severe personal injury, death
orsubstantialpropertydamage.Beforestartingthe
boiler . . .
• SeeSparkIgnitionControlSupplementforOperat-
ingInstructions
• Verifytheboilerandsystemwaterleveliscorrect(no
morethan½ofgaugeglassorlessthan¼”above
bottomofgaugeglass).
• Verify the “Preparation” procedures, on previous
page, have been completed.
GSA
Gas-Fired Steam Boilers – Boiler Manual
19
Part Number 550-110-738/1012
7 Start-up continued
Verify operation
Check burner flame — Pilot burner
Proper pilot flame (see Figure 19):
1. Blueame.
2. Innerconeengulngthermocouple.
3. Thermocouple glowing cherry red.
Improper pilot flame:
1. Overfired—Largeameliftingorblowingpastthermocouple.
2. Underred — Small ame. Inner cone not engulng
thermocouple.
3. Lackofprimaryair—Yellowametip.
4. Incorrectlyheatedthermocouple.
Check burner flame — Main burner
Proper main burner flame (see Figure 20):
1. Yellow‑orangestreaksmayappear(causedbydust).
Improper main burner flame:
1. Overred—Largeames.
2. Underred—Smallames.
3. Lackofprimaryair—Yellowtippingonames(sootingwill
occur).
Figure 19 Typical pilot burner flame
Check vent damper operation
1. Raiseroomthermostattocallforheat—Ventdamperactuator
will slowly open vent damper.
2. Whenventdamperisfullyopen—Maingasvalvewillopen
and main burners will ignite.
Ventdampermustbefullyopenbeforemainburn-
erslight.Ifventdamper does not fully open, ue
products such as carbon monoxide will escape into
house, causing severe personal injury or death.
3. Lowerthermostatsetting—Mainburnerameswillgoout,
then vent damper will close.
4. RepeatSteps1through3severaltimestoverifyoperation.
5. Return thermostat to normal setting.
6. Set thermostat heat anticipator setting indicated on wiring
diagram.
Check venting system operation
Withboilerring,holdacandleormatchbelowloweredgeofdraft
hood“skirt.”Ifamedoesnotblowout,butburnsundisturbed,
theventsystemisworkingproperly.Ifameblowsoutorickers
severely,the ventsystemmustbechecked forobstructions or
othercausesofimproperventing.
Figure 20 Typical main burner flame
GSA
Gas-Fired Steam Boilers – Boiler Manual
20 Part Number 550-110-738/1012
8 Checkout procedure
o Boilerandheatdistributionunitslledwithwater?
o Boilersproperlyskimmed?
o Airpurgedfromgaspiping?Pipingcheckedforleaks?
o Correctly‑sized manifold orifices installed? SeeTable3,
page7,tochecksizeandfueltype.
Correctlysizedmanifoldoricesmustbeused.
Failure to do so will cause severe personal injury,
death or substantial property damage.
o Buttononspillswitchpushedin?
o FollowOperatingInstructionsinControlSupplementforproper
start‑up?
o Properburnerameobserved?See“Verifyoperation,”page
19.
oTest limit control — While burners are operating, move
indicator on limit control below actual boiler pressure.
Burners should go off. Raise setting on limitcontrol above
boiler pressure and burners should reignite.
o Testlowwatercutoff—Checkprobe‑typelowwatercutofffor
proper operation.
a. Turnoffpowertoboilerandwait5minutes.
b. Drainwatertobottomofgaugeglass.
c. Turn on power.
d. Setthermostattocallforheat.Redneonlamponlower
watercutoffshouldlight.
e. Wait 5 minutes. Boiler should not fire.
f. Rellboilertocorrectwaterline.Redlampshouldgooff.
g. Wait 5 minutes. Boiler should fire.
h. Return thermostat to normal setting.
oTest additional eld‑installed controls — If boiler has an
additionalhighlimit,lowwatercutofforothercontrols,test
foroperationasoutlinedbymanufacturer.Burnersshouldbe
operatingandshouldgooffwhencontrolsaretested.When
controls are restored, burners should reignite.
o Testignitionsystemsafetydevice—
Installation and Service Certificate
Boilermodel__________________Series__________CPnumber___________Dateinstalled_______________
MeasuredBtuhinput____________
Installer______________________________________________________________________________________
(company) (address) (phone)
_____________________________________
(installer’ssignature)
o Installationinstructionshavebeenfollowed.
o Check‑outsequencehasbeenperformed.
o Aboveinformationiscertiedtobecorrect.
o Informationreceivedandleftwithowner/maintenanceperson.
Spark ignition boilers:Connectmanometertooutletside
ofgasvalve.Startboiler,allowingfornormalstart‑upcycle
to occur and main burners to ignite. With main burners on,
manually shut off gas supply at manual main shutoff gas
valve.Burnersshouldgooff.Openmanualmainshut‑offgas
valve.Manometershouldconrmthereisnogasow.Pilot
willrelight,amesensingelementwillsensepilotameand
mainburnersreignite.Putboilerbackintooperation.
o Setlimitcontrol(s)tosystempressurerequirements.Adjust
balancing valves and controls to provide design pressure to
system.
o Verifythermostatheatanticipator(ifavailable)setproperly?
See“Thermostat”,page16.
o Cycleboilerwiththermostat—Raisetohighestsettingand
verify boiler goes through normal start‑up cycle. Lower to
lowestsettingandverifyboilergoesoff.
o Measurenaturalgasinput:
a. Operate boiler 10 minutes.
b. Turnoffotherappliances.
c. Atnaturalgasmeter,measuretime(inseconds)required
touseonecubicfootofgas.
d. Calculategasinput:
3600 x 1000
number of seconds from step c
= Btuh
e. Btuh calculated should approximate input rating on boiler
rating label.
o Checkmanifoldgaspressurebyconnectingmanometer to
downstreamtesttappingonmaingasvalve.Manifoldpressure
fornaturalgasshouldbe3.5”w.c.andforpropanegasshould
be 10” w.c.
o Observeseveraloperatingcyclesforproperoperation.
oSet room thermostat to desired room temperature.
o Fillin“Installationandservicecerticate”below?
oReview all instructions shipped with this boiler with owner or
maintenance person. Return instructions to envelope and give
toownerorplaceinpocketinsidefrontpanelinboiler.
This manual suits for next models
7
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