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

•CPnumberfromtheboilerjacket.YoumaylisttheCPnumberinthespaceprovidedonthe“Installationandservice

certicate”foundonpage20.

Contents Page

1 Prepare boiler location .......................................................2

2 Prepare boiler .....................................................................8

3 Installpiping .....................................................................11

4 Installcontrols ..................................................................14

5 Installgaspiping ...............................................................15

6 Field Wiring ...................................................................... 16

7 Start-up ............................................................................ 17

8 Checkoutprocedure ......................................................... 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 —Readallinstructionsbeforeinstall-

ing. Read page 2 ﬁrst. Follow all instructions in

proper order to prevent personal injury or death.

• Considerpipingandinstallationwhendetermining

boiler location.

• Anyclaimsfordamageorshortage in shipment

must be ﬁled immediately against the transporta-

tion company by the consignee.

• GSAboilerscannotbeadaptedforheateruse.

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.

• PleaseseetheUser’sInformationManualforyour

reference.

• Have the boiler serviced byaqualied service

technician, at least annually.

INSTALLER —

Spark ignition boilers — Refertothismanual

forgeneralinstallationandmaintenanceinforma-

tion.ReferalsototheGSASparkIgnitionControl

Supplement,partnumber550‑141‑971,foroperat-

ing instructions, troubleshooting and other additional

information for GSA boilers equipped with spark

ignition.

GSA

Gas-Fired Steam Boilers – Boiler Manual

Part Number 550-110-738/1012

This manual must only be used by a qualiﬁed

heating installer/service technician. Read

theseinstructionscompletelybeforebeginningthe

installation.Failuretofollowtheseinstructionscan

cause severe personal injury, death or substantial

property damage.

Improper  installation,  adjustment,  alteration,  service or

maintenance can cause property damage, personal injury,

exposuretohazardousmaterials,orlossoflife.Refertothe

User’sInformationManualprovidedwiththisboiler.Installation

andservicemustbeperformedbyaqualiedinstaller,service

agencyorthegassupplierwhomustreadandfollowthe

suppliedinstructionsbeforeinstalling,servicingorremovingthis

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.Usecarewhenhandlingthese

materials per instructions on page 25 of this

manual. Failure to comply could result in severe

personal injury.

When servicing boiler —

1. Toavoidelectricshock,disconnectelectricalsupplybefore

performingmaintenance.

2. Toavoidsevereburns,allowboilertocoolbeforeperforming

maintenance.

Boiler operation —

3. Donotblockowofcombustionorventilationairtoboiler.

4. Shouldoverheatingoccur,turnoffordisconnectelectrical

supplytoboilerandshutoffthegassupplyatalocation

externaltotheappliance,ifpossible.

5. Donotusethisboilerifanyparthasbeenunderwater.

Immediatelycallaqualiedservicetechniciantoinspectthe

boilerandtoreplaceanypartofthecontrolsystemandany

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,causingleakagebetweenboilersections,circulator

anges,diaphragmtanksorothersystemcomponents.This

can result in substantial property damage.

7. DONOTuse“homemadecures”or“boilerpatent

medicines”. Serious damage to boiler, personnel and/or

property may result.

8. Continualfreshmakeupwaterwillreduceboilerlife.Mineral

buildupinsectionsreducesheattransfer,overheatscast

iron, and causes section failure. Addition of oxygenand

othergasescancauseinternalcorrosion.Leaksinboileror

pipingmustberepairedatoncetopreventmakeupwater.

9. Donotaddcoldwatertohotboiler.Thermalshockcancause

sectionstocrack.

1 Prepare boiler location

Codes & Checklist

Installations must follow these codes:

• Local,state,provincial,andnationalcodes,laws,regulations

and ordinances.

• NationalFuelGasCode,ANSIZ223.1–latestedition.

• StandardforControlsandSafetyDevicesforAutomatically

FiredBoilers,ANSI/ASMECSD‑1,whenrequired.

• NationalElectricalCode.

• ForCanadaonly:B149.1orB149.2InstallationCode,CSA

C22.1CanadianElectricalCodePart1andanylocalcodes.

Certiﬁcation

 TheGSAboilergasmanifoldandcontrolsmetsafe

Lightingandotherperformancecriteriawhenboiler

underwent tests specied in ANSI Z21.13–latest

edition.

Before locating the boiler:

o Checkfornearbyconnectionto:

• Ventingconnections

• Gassupplypiping

• Electricalpower

o Checkareaaroundboiler.Removeanycombustiblematerials,

gasolineandotherammableliquids.

 Failuretokeepboilerareaclearandfreeofcom-

bustible materials, gasoline and other ammable

liquids and vapors can result in severe personal

injury, death or substantial property damage.

o Boiler must be installed so that gas control system components

areprotectedfromdrippingorsprayingwaterorrainduring

operation or service.

o Ifnewboilerwillreplaceexistingboiler,checkforandcorrect

system problems, such as:

• Systemleakscausingoxygencorrosionorsectioncracks

fromhardwaterdeposits.

Read this ﬁrst!

GSA

Gas-Fired Steam Boilers – Boiler Manual

Part Number 550-110-738/1012

1 Prepare boiler location continued

Clearances

Recommended SERVICE clearances

1. Provideminimumclearancesforcleaningandservicingthe

boilerandforaccesstocontrolsandcomponentsaslistedin

the table at right.

2. Provideatleastscrewdriverclearancetojacketfrontpanel

screwsforremovaloffrontpanelforinspectionandminor

service.Ifunabletoprovideatleastscrewdriverclearance,

installunionsandshutoffvalvesinsystemsoboilercanbe

movedforservicing.

Figure 1 Alcove installations

Minimum clearances to COMBUSTIBLE

materials

General clearances

— All installations

1. See the table at right for clearances to boiler and system

components.

2. ClearancestoTypeBventmaterialsareasspeciedbythe

ventmanufacturer.

Alcove (not closet) installations only

 GSAboilersarenotapprovedforcloset installation

 ––onlyforalcoveinstallation,withminimum

clearancestocombustiblesurfacesasshowninthe

tableatright.SeeFigure1.Thefrontsidemustbe

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

Part Number 550-110-738/1012

1 Prepare boiler location continued

Vent System

 Failuretofollowallinstructionscanresultinuegas

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.

 Donotalterboilerdrafthoodorplaceanyobstruc-

tion or non-certiﬁed vent damper in breeching or

ventsystem. CSA certication will become void.

Flue gas spillage and carbon monoxide emissions

will occur causing severe personal injury or death.

 Thefollowingrequirementsapplywhenyouremove

anexistingboilerfromaventsystemsharedwith

other appliances. If the new boiler will not use the

common vent, you must test (as described below)

eachremainingappliance—operatingbyitself—to

verifythattheventsystemoperatesadequately.

When removing boiler from existing common vent

system:

Atthetimeofremovalofanexistingboiler,thefollowingsteps

shall be followed with each appliance remaining connected to

the common venting system placed in operation, while the other

appliances remaining connected to the common venting system

are not in operation.

a. Seal any unused openings in the common venting system.

b. Visuallyinspecttheventingsystemforpropersizeand

horizontalpitchanddeterminethereisnoblockageor

restriction,leakage,corrosionorotherdeciencieswhichcould

causeanunsafecondition.

c. Testventsystem—Insofarasispractical,closeallbuilding

doors and windows and all doors between the space in which

the appliances remaining connected to the common venting

system are located and other spaces of the building.Turn

on clothes dryers and any appliance not connected to the

commonventingsystem.Turnonanyexhaustfans,suchas

range hoods and bathroom exhausts, so they will operate at

maximumspeed.Donotoperateasummerexhaustfan.Close

ﬁreplace dampers.

d. Place in operation the appliance being inspected. Follow the

operatinginstructions.  Adjust thermostat so appliance will

operate continuously.

e. Testforspillageatdrafthoodreliefopeningafter5min-

utesofmainburneroperation.Usetheameofamatchor

candle.

f. Afterithasbeendeterminedthateachapplianceremaining

connected to the common venting system properly vents when

testedasoutlinedabove,returndoors,windows,exhaustfans,

ﬁreplace dampers, and any other gas-burning appliance to

theirpreviousconditionsofuse.

Anyimproperoperationofthecommonventingsystemshouldbe

correctedsotheinstallationconformswiththeNationalFuelGas

Code,ANSIZ223.1/NFPA54and/orCAN/CGAB149,Installation

Codes.Whenresizinganyportion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 the National Fuel Gas Code, ANSIZ223.1/NFPA54 and/or

CANCGAB149,InstallationCodes.

Residential garage installation

Takethefollowingspecialprecautionswheninstallingtheboilerin

aresidentialgarage.Iftheboilerislocatedinaresidentialgarage,

perANSIZ223.1:

• Mounttheboileraminimumof18inchesabovetheoorof

the garage to assure the burner and ignition devices will be

nolessthan18inchesabovetheoor.

• Locateorprotecttheboilersoitcannotbedamagedbya

moving vehicle.

Flooring and foundation

 Donotinstallboileroncombustibleooringor

carpetingevenifaconcreteoraeratedfoundation

is used. Fire can result, causing severe personal

injury, death or substantial property damage.

1. Provideasolidbrick orminimum2‑inchthick concrete

foundationpadifanyofthefollowingistrue:

• oorcanbecomeooded.

• theboilermountingareaisnotlevel.

2. SeeTable1forminimumfoundationdimensions.

3. Useafoundationwithairwayswhen:

• Electricalwiringortelephonecablesburiedintheconcrete

ooroftheboilerroom.

• Concreteooris“green”.

• Waterischanneledundertheconcrete.

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

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

Pleasereviewthefollowinginformationonpotentialcombustion

air contamination problems.

SeeTable2forproductsandareaswhichmaycausecontaminated

combustion air.

 To prevent potential of severe personal injury or

death, checkforproducts or areas listed below

beforeinstallingboiler.Ifanyofthesecontaminants

arefound:

•Removecontaminantspermanently.

— OR —

 •Isolateboilerandprovideoutsidecombustion

air.Seenational,provincialorlocalcodesfor

furtherinformation.

Table 2 Corrosive contaminants and likely locations

Vent System

Chimney or vent requirements

1. VentingmustbeinstalledaccordingtotheNationalFuelGas

Code, ANSI Z223.1–latest edition and applicable building

codes. Canadian installations must comply with B149.1 or

B149.2InstallationCodes.

2. See“Ratings”onpage31forminimumchimneyorventsizes.

Chimneyorventtermination:

• Achimney,oranyventotherthanaTypeBventwithlisted

ventcap,mustextendatleast3feetabovethe highest

pointwhereitpassesthrougharoofofabuilding,andat

least2feethigherthananyportionofabuildingwithina

horizontaldistanceof10feet.

• TypeBventswithlistedcapsmayterminateasinFigure2

ifnocloserthan8feetfromaverticalwallorsimilar

obstruction.

• Otherwise,Type B vents must terminate at least 2 feet

abovetheroofpenetrationandatleast2feethigherthan

anyportionofabuildingwithin10feet.

3. Alinedchimneyispreferredandmustbeusedwhenrequired

by local, state, provincial and national codes, laws, regulations

and ordinances.Vitreoustile linings with joints that prevent

retentionofmoistureandliningsmadeofnoncorrosive

materialsarebest.Adviceforueconnectionsandchimney

liningscanbeobtainedfromlocalgasutility.TypeBdouble‑

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

damperisventedthroughthistypeofchimney,thepotential

existsforcondensationtooccur.Condensationcandamagea

masonrychimney.Thefollowingarerecommendedtoprevent

possible damage.

a. Line chimney with corrosion-resistant metal liner such as

AL29‑4C®single‑wallstainlesssteelorB‑vent.Sizeliner

perNationalFuelGasCodeANSIZ223.1–latestedition.

b. Provide drain trap to remove any condensate.

5. Where two or more gas appliances vent into a common

chimneyorvent,equivalentareashouldbeatleastequalto

areaofventoutletonlargestapplianceplus50percentofvent

outletareaofadditionalappliances.

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 renishing 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

Part 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. Moveentirecrateandpalletnexttoselectedlocation.

3. Remove crate. Leave boiler on pallet.

4. Unboltboilerfrompallet.

5. Removeboilerfrompallet.

 Provideadequatecombustionandventilationairto

assurepropercombustionandreducetheriskof

severe personal injury, death or substantial property

damage caused by ue gas spillage and carbon

monoxide emissions.

Combustionairandventilationopeningsmustcomplywith

theNationalFuelGasCode,ANSIZ223.1–latestedition,orap-

plicablelocalbuildingcodes.Canadianinstallationsmustcomply

withB149.1orB149.2InstallationCodes.

Air opening sizes in the following are givenin free area (after

correctionforlouverobstruction).

Option 1 — Provide (2) openings:

Option 2 — Provide (1) opening:

Asinglecombustionairopeningcanbeused,provided:

• The

openingmustcommencewithin12inchesofthe ceiling.

• Theboilermusthaveclearancesofatleast1inchfromboth

sidesandback,and6inchesfromthefront.

• The opening must connect directly to the outdoors or to a

space that communicates directly to the outdoors.

• Theaircanbeprovidedthroughadirectopeningorthrough

a horizontal or vertical duct.

• Thefreeareaoftheopeningmustbeatleastequaltothe

sumofallventconnectorsinthespace.

• Thefreeareaoftheopeningmustbeatleast1squareinch

per3000Btu/hrinputratingofallequipmentlocatedinthe

space.

Tight construction — Deﬁnition:

Tightconstructionmeans(perANSIZ223.1):

• Wallsandceilingsexposedtotheoutsideatmospherehave

acontinuouswatervaporretarderwitharatingof1permor

lesswithopeningsgasketed.AND

• Weather‑strippinghasbeenaddedonopenablewindowsand

doors.AND

• Caulking or sealants are applied to areas such as joints

aroundwindowsanddoorframes,betweensoleplatesand

oors, between wall‑ceiling joints, between wall panels, at

penetrations forplumbing, electrical, and gas lines,and in

other openings.

Tight construction requirements

Ifbuildingisoftightconstructionandairistakenfrominsidethe

building, provide two openings in building outside wall, one within

12inchesofceiling,theotherwithin12inchesoftheoor.Each

openingmusthaveaminimumfreeareaof1squareinchper

1,000Btuhofallappliancesinthebuilding.

Exception

NO combustion air openings are needed when the boiler (and

other appliances) are installed in a space with a volume NO

LESSthan50cubicfeetper1,000Btuhofallinstalledappliances.

Sumthe total input of all appliances inMBH (1,000’s of Btuh)

andmultiplythisnumbertimes50.BuildingmustnotbeofTight

construction (see above).

Example:Fortotalinputof100MBH(100,000Btuh),minimum

volumeis50x100=5,000cubicfeet.Ataceilingheightof8feet,

spacemusthaveatleast5,000÷8=625squarefeet(25feetx

25feet,forinstance).

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

requiredfor thering rateofallappliances,butalsotohandle

theairmovementrateoftheexhaustfansorairmoversusingair

fromthebuildingorspace.

Motorized air dampers

Iftheairopeningsarettedwithmotorizeddampers,electrically

interlockthedamperto:

• Preventtheboilerfromringifthedamperisnotfullyopen.

• Shuttheboilerdownshouldthedampercloseduringboiler

operation.

Toaccomplishthisinterlock,wireanisolatedcontact(provingthe

damper open) in series with the thermostat input to the boiler. The

boilerwillnotstartifthisdamperisclosed,andwillshutdown

should damper close during operation.

Placement and setup

GSA

Gas-Fired Steam Boilers – Boiler Manual

Part Number 550-110-738/1012

1 Prepare boiler location continued

Setup - continued

Inspect oriﬁces and burners

1. Removefrontjacketdoor.Removebaseaccesspanel(see

Figure 20, item 14, page 26).

2. Checkforcorrectly‑sizedmanifoldorices.SeeTable3

for sizing. (The orice size is stamped on the orice spud

barrel.)

 Correctly‑sized manifold orices 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

restwiththeiropeningsfaceup.Mainburnerorices

mustinjectdowncenterofburner.Failuretoproperly

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

amerolloutonignitionofmainame,resultingin

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. Donotusegaugesuppliedwithboilerforpressuretesting.

Installgaugewithappropriaterange.

Fill and pressure test

1. Fill boiler with water.Vent all air.Test boilers between 45‑

50 psi.

 Donotleaveboilerunattended.Acoldwaterllcould

expand and cause excessive pressure resulting in

severe personal injury, death or substantial property

damage.

2. Checkforstablegaugepressureformorethan10minutes.

Visuallycheckforleaksifgaugepressuredrops.

Do not use petroleum based cleaning or sealing

compounds in boiler system. Severe damage to

boiler will result, causing substantial property

damage.

2. Retestboilerafterrepairingleaks.

3. Removeplugsfromanytappingsthatwillbeusedforcontrols

andaccessories.RefertoTable4andFigure3.

 Float‑type low water cutoff — If eld installing a

oat‑typelowwatercutoff,itmustbepipedonlyto

the gauge glass tappings, items H, Figure 3. The

tappingsarespaced9”oncenter.Useonlyoat‑type

lowwatercutoffswithquick‑connecthookupsthat

willprovidealowwatercutoffpointnohigherthan

2”abovethecenterofthebottomtapping.Seepage

14,Figure16,foratypicalinstallation.

Pressure test - continued

Table 4 Control tapping

Figure 3 Control tapping locations

Drain and remove ﬁttings

1. Drainboilerandrepairleaksiffound.

 Leaksmustbe repairedatonce.Failure todoso

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

C ¾”

Probe-typelow water cutoff

D ¾”

Drain

E ¾”

Relief valve

G ¾”

Plugged

H ½”

Gauge glass and/or optional

low water cutoff

(See Note)

⅜”

Tricock tappings

L ½”

Siphon, pressure gauge, high

limit control

S 1 ½”

Skim tapping

Note: Available only on special request.

GSA

Gas-Fired Steam Boilers – Boiler Manual

Part Number 550-110-738/1012

2 Prepare boiler continued

Installation of drawer assembly,

front base panels –

1. SeeFigure6.Fastenfrontbasepanel(6 Z\, inch high)

and rear base channel to section assembly. Seal with

boilercementalongtopofinsulationpanels.

2. Theburnerdrawerassemblyconsistsoftheburner

drawer, main burners, gas manifold, pilot burner,

etc.

3. CheckforproperoricesizingfromTable3,page7

inGSAboilermanual.

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

backburnersupportwithopeningsfacing

up.Gasoricesmustinjectdowncenter

ofburner.Failuretoproperlyseatburners

will result in severe personal injury, death

or substantial property damage.

7. Installrolloutthermalfuseelementwithwiretermi-

nalsfacinguponfrontaccesspanelasshownin

Figure10.WirepertheappropriateControlSupple-

ment.

Inspect burners – GSA 300 boiler

1. AllunitsexceptGSA‑300arefactory‑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)

SetuecollectorhoodonboilerasshowninFigure4.Useboiler

cementfurnishedtoprovidegas‑tightseal.

Failuretomaintaingas‑tightsealcancauseuegas

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 ( 7 B\zn inch high) and rear

base channel to section assembly. Seal with boiler cement along

topofinsulationpanels.

 Failuretomaintaingas‑tightsealcancauseuegas

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

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.SeeFigure20,items1and9,onpage26.Useboiler

cement to provide gas tight seal.

 Failuretomaintaingas‑tightsealcancauseuegas

spillage and carbon monoxide emissions, resulting

in severe personal injury or death.

 Donotalterboilerdrafthoodorplaceanyobstruction

or non-approved vent damper in breeching or vent

system.CSAcerticationwillbecomevoid.Fluegas

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

Burner

Pilot burner

Pilot

Legend:

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 (uptoGSA‑300)

1. Removetheproperknockoutdiscsfrompanelsasshown

in Table 4, page 7.

2. FollowJacketInstructionsinjacketcarton.

Spill switch installation

1. FastenspillswitchtodrafthoodasshowninFigure20,item

20, page 26.

2. SeewiringdiagraminGSASparkIgnitionControlSupple-

ment to connect wires.

GSA

Gas-Fired Steam Boilers – Boiler Manual

Part Number 550-110-738/1012

Vent damper

Damper blade

Seeventmanufacturer’sinstructionstoinstallplug(shippedwith

damper)indamperhole.Installplugwith3/8”diameterholein

vent damper hole.

1. Installventdamperasshowninventdampermanufacturer’s

instructions.Ventdampermustbeinstalledsothatitserves

only one boiler and so damper blade indicator is visible to the

user. See Figure 11.

2. Screwsorrivetsusedtosecuretheventdampertothedraft

hoodmustnotinterferewithrotationofthedamperblade.

3. Installdamper harnessbetweendamperactuatorand

knockoutinjackettoppanel.Usestrainreliefconnectorsand

locknutstosecurebothendsofdamperharness.

 Keepwiringharnessclearofallhotsurfaces.Wire

insulationcouldbedamaged,causingriskof

electrical short-circuit.

4. Read and apply the harness plug warning label (shown above)

sothatitisvisibleafterinstallation

Damper installation

Figure 11 Vent damper assemblies

These systems are used on gas-ﬁred boilers with

ventdampersasshippedfromfactory.Boilerwillnot

operate without vent damper installed.

Minimum clearances

Provide a minimum of 6” between the ventdamper and any

combustiblematerial.(See“Minimumclearancetocombustible

materials,”page3,forminimumclearancefromjackettopto

ceiling to maintain this dimension.).

 Donotmodifydrafthoodorventdamper,ormake

another connection between draft hood and vent

damper or boiler except as noted below. This will

voidCSAcertication andwillnotbecovered by

warranty.Anychangeswillcauseseverepersonal

injury, death or substantial property damage.

2 Prepare boiler continued

5. Plug damper harness receptacle into damper harness plug.

 Bypassing(jumpering)ventdamperwillcauseue

products such as carbon monoxide to escape into

the house. This will cause severe personal injury or

death.

 Afterboilerhasoperatedonce,ifeitherendofhar-

nessisdisconnected,thesystemsafetyshutdown

will occur. The boiler will not operate until harness

is reconnected.

 Efkal or Field Control dampers — Damper hold

openswitchmustbeinAutomaticOperationposition

forsystemtooperateproperly.

Install vent piping

1. Connectfromdrafthoodorventdamperoutlettochimneyor

vent with same size vent connector.

2. Wherepossible,verticalventingtotheoutsidefromthedraft

hoodorventdamperoutletwillofferbestperformance.

3. Where horizontal vent connector is used, slope upward at

least¼”perlinealfoottowardchimneyorventandsupport

with hangers to prevent sagging.

4. Breechingmustnotbeconnectedtoanyportionofa

mechanicaldraftsystemthatcanoperateunderpositive

pressure.

Long horizontal vent connector, excessive number

ofelbowortees,orotherobstructionsthatrestrict

theowofcombustiongasesshouldbeavoided.

Severe personal injury, death or substantial property

damage could result.

GSA

Gas-Fired Steam Boilers – Boiler Manual

Part Number 550-110-738/1012

3 Install piping

General

1.  Pipe before installing controls. Connect return piping after

jacketisattached.Connectsupplypipingbeforeorafterjacket

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. Satisfactory operationofasteamheatingsystemdepends

onadequatecondensatereturntoboilertomaintainasteady

waterlevel.Avoidaddingrawmakeupwater.Whereconden-

satereturnisnotadequate,refertorecommendationson

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

ApplytherecommendedpipinginFigures12and14onlywhen

connectingtoaparallel‑owsystem.Whenconnectingtoa

counterowsystem,theboilersteamsupplymustconnectinto

thetopofthecounterowsystemheader,asshowninFigure13.

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

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,toreducethepotential forbodily

injury and property damage, a discharge line

MUSTbeinstalledthat:

• Isconnectedfromtheoutlettoasafepoint

ofdischargewithnointerveningvalve.

• 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

riskoffreezing.

• Is,overitsentirelength,ofapipesizeequal

toorgreaterthanthatofthevalveoutlet.

 Useonlyschedule40metalpipefordischarge.

(Do not use schedule 80, extra strong or

double strong pipe or connections.) DO NOT

CAP, PLUG OR OTHERWISE OBSTRUCT

DISCHARGEPIPEOUTLET!Ifdischargeis

piped upward, a condensate drain must be

provided in the elbow below the vertical pipe

topreventcondensatefromreturningintothe

valve. Failure to comply with these instructions

willcauseadangeroussprayofhotwaterand

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.

• Wheninstallingthereliefvalve,ensurethat

all connections, including the valve inlet, are

cleanandfreefromanyforeignmatter.

• Mountthe relief valve only in the vertical

position, directly connected to the tapping

designatedinthemanualontopoftheboiler.

• Use pipe compound sparingly, or tape, on

external threads only.

• Donotuseapipewrench!Usepropertype

and size wrench on wrench pads only.

Installreliefvalveintappingontopofboiler.SeeTable4,

page7,forcontroltappinglocations.Seethetagattached

tothereliefvalveformanufacturer’sinstructions.

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 ¾

½ 1 ½

GSA-125/150

125 1 ¼ 1 ¼

2 ¼

Use boiler feed

system

GSA-175

150

½ 1 ½

GSA-200

175 1 ¾ 1 ¾

Use boiler feed

system

GSA-250

225

GSA-300

250

2 ¼

Designed full capacity steaming time of modern boilers is 10 minutes.

GSA

Gas-Fired Steam Boilers – Boiler Manual

Part Number 550-110-738/1012

3 Install piping continued

Condensate return

Modernsteamboilersaredesignedtosteamforlesstimethan

older, larger boilers. When replacing an older steam boiler the

system condensate return time may be longer than the steaming

time.Thiscouldcausethefollowingproblems:

1. Boilersttedwithanautomaticwaterfeedcouldoverll.

2. Unitsttedwithonlyalowwatercutoffwouldshutdownand

cyclewhilewaitingforcondensatetoreturn.

Followingisasimplemethodfordeterminingwhetherornota

reservoirpipeisrequiredtolengthensteamingtimefora

residential installation:

1. Disconnect condensate return line at existing boiler.

2. Heat

boilerandallowtosteamfor10minutes.Turnoff boiler.

3. Measurelengthoftimefromwhenboilerstartedtosteamto

when condensate begins to return through condensate line.

4. Measurelengthoftimefromwhencondensatebeginstoreturn

to when it stops returning. Divide this time by 2.

5. Addtimemeasuredinstep3totimecalculatedinstep4.This

sumistheaveragetimerequiredforcondensatetoreturnto

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

morethan10minutes,areservoirpipe(orboilerfeedsystem)

isrecommended.SeeTable7,page12,forsuggestedreservoir

pipesize.InstallasshowninFigure14.

Forlargersystems(asnotedinTable7),useaboilerfeedsystem

withacondensatetankandfeedpump.Youwillhavetoinstalla

lowwatercutoff/pumpcontrolontheboilertooperatethepump.

UseTable8tosizeboilerfeedsystems.Seepage7,Table4,for

tappinglocations.(Theuseofacombinationcondensatetankand

oat‑controlledcondensatereturnpumpisnotrecommended.)

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

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. ControlsaremountedandwiredasshowninFigure15.for

actual tapping locations see Table 4 and Figure 3 on

page 7.

2. Bringsupplywiringtoboiler.Mustbe14gaugeorheavier.

3. SeewiringdiagramintheGSASparkIgnitionControlSupple-

ment.

Figure 15 Controls

Float-type low water cutoff (when provided by others)

1. InstalllowwatercutoffasshowninFigure16,below.SeeTable

4andFigure3onpage7foractualtappinglocation.

2. Installblowdownlineinbottomofcutoff.Seecontrol

manufacturer’sinstructionsfordetails.

 Pipeblowdownlinenearoorclosetooordrain

toeliminatepotentialofsevereburns.Donotplug,

valve or place any obstruction in blowdown line.

3. Waterfeedersarenotrecommendedforprimarycontrol.A

lowwatercutoffwithpumpcontrollerisrecommendedwitha

condensatereceiverandfeedpump.

Figure 16 Float-type low water cutoff

(when provided by others)

GSA

Gas-Fired Steam Boilers – Boiler Manual

Part Number 550-110-738/1012

5 Install gas piping

Connecting gas supply piping to boiler

1. RemovejacketfrontpanelandseeFigure17topipegasto

boiler.

a. Installdriplegatinletofgasconnectiontoboiler.Where

localutilityrequiresdriplegtobeextendedtotheoor,

useappropriatelengthofnipplebetweencapandtee.

b. Installgroundjointunionforservicing,whenrequired.

c. Installmanualshutoffvalveingassupplypipingoutside

boilerjacketwhenrequiredbylocalcodesorutility

requirements.

d. InCanada—Whenusingmanualmainshutoffvalve,it

must be identiﬁed by the installer.

2. Support

piping with hangers, not by boiler or its accessories.

3. Purgeallairfromgassupplypiping.

4. Beforeplacingboilerinoperation,checkboileranditsgas

connectionforleaks.

a. Close manual main shutoff valve during any pressure

testing at less than 13” w.c.

b. Disconnectboilerandgasvalvefromgassupplypiping

during any pressure testing greater than 13” w.c.

 Donotcheckforgasleakswithanopename—Use

bubbletest.Failuretousebubbletestorcheckfor

gasleakscancauseseverepersonalinjury,death

or substantial property damage.

5. Usepipedopecompatiblewithpropanegases.Applysparingly

onlytomalethreadsofpipejointssothatpipedopedoesnot

blockgasow.

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. SeeTable9 forpipelengthanddiameter.   Base onrated

boiler inp

ut,foundonpage31(divideby1,000toobtaincubic

et per hour). Table9isonly forgas with specic gravity

0.60,withapressuredropthroughthegaspipingof0.30”w.c.

Foradditionalgaspipesizinginformation,seeANSIZ223.1

(B149.1orB149.2forCanadianinstallations).

2. Inletpressurerequiredatgasvalveinlet:

• Maximum:13”w.c.

• Minimum:5”w.c.

• Manifoldgaspressure:3.5”w.c.

3. Install100%lockupgaspressureregulatorinsupplylineif

inletpressureexceeds13”w.c.Adjustfor13”w.c.maximum.

Propane Gas:

1. Contactgassuppliertosizepipes,tanksand100%lockup

gas pressure regulator.

2. Adjustpropanesupplyregulatorprovidedbygassupplierfor

13” w.c. maximum pressure.

3. Inletpressurerequiredatgasvalveinlet:

• Maximum:13”w.c.

• Minimum:11”w.c.

• Manifoldgaspressure: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

Part Number 550-110-738/1012

6 Field wiring

 Foryoursafety,turnoffelectricalpowersupplyat

serviceentrancepanelbeforemakinganyelectrical

connectionstoavoidpossibleelectricshockhazard.

Failure to do so can cause severe personal injury

or death.

 WiringmustbeN.E.C.Class1.

 Ifrollout 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°Cwireorequivalent.

 Boiler must be electrically grounded as required

byNationalElectricalCodeANSI/NFPA70–latest

edition.

Electrical installation must comply with:

1. NationalElectricalCodeandanyothernational,state,

provincial or local codes or regulations.

2. InCanada,CSAC22.1CanadianElectricalCode,andany

local codes.

Wiring connections

Boiler is shipped with controls completely wired, except spill switch

andventdamper.SeewiringdiagramintheGSASparkIgnition

ControlSupplement.

Thermostat

1. Connectthermostatasshownonwiringdiagramonboiler.

2. Installoninsidewallawayfrominuencesofdrafts,hotor

cold water pipes, lighting ﬁxtures, television, sunrays or

ﬁreplaces.

3. Ifthermostathasaheatanticipator,setheatanticipatorin

thermostattomatchpowerrequirementsofequipment

connected to it. See boiler wiring diagram (on boiler, or in

SparkIgntionControlSupplement)forrecommendedsetting.

Forotherdevices,seemanufacturer’sspecications.Wiring

diagramonboilergivessettingforcontrolmoduleandgas

valve.Alsoseeinstructionswiththermostat.

Junction box

Connect120VACpowerwiring(Figure18).Aseparateelectrical

circuitwithafuseddisconnectswitch(15amp.recommended)

shouldbeusedfortheboiler.

Figure 18 Field wiring connections — service switch and thermostat (or end switch) provided by installer

GSA

Gas-Fired Steam Boilers – Boiler Manual

Part Number 550-110-738/1012

7 Start-up

Preparation

Check for gas leaks

Before starting the boiler, and during initial opera-

tion,smellneartheoorandaroundtheboilerfor

gas odorant or any unusual odor. Do not proceed

withstart‑upifthereisanyindicationofagasleak.

Repairanyleakatonce.

 Propaneboilersonly—Yourpropanesuppliermixes

anodorantwiththepropanetomakeitspresence

detectable.Insomeinstances,theodorantcanfade

and the gas may no longer have an odor.

• Propanegascanaccumulateatoorlevel.Smell

neartheoorforthegasodorantor anyunusual

odor.Ifyoususpectaleak,donotattempttolight

the pilot.

• Usecautionwhenattemptingtolightthepropane

pilot.Thisshouldbedonebyaqualiedser-

vicetechnician,particularlyifpilotoutagesare

common.

• Periodicallychecktheodorantlevelofyourgas.

• Inspectboilerandsystematleastyearlytomake

sureallgaspipingisleak‑tight.

• Consultyourpropanesupplierregardinginstallation

ofagasleakdetector.Therearesomeproductson

themarketintendedforthispurpose.Yoursupplier

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.

 Eliminateallsystemleaks.Continualfreshmakeup

waterwillreduceboilerlife.Mineralscanbuildup

insections,reducingheattransfer,overheatingcast

iron,andcausingsectionfailure.

Consultlocalwatertreatmentcompaniesforunusuallyhardwater

areas (above 7 grains hardness) or low pH water conditions (below

7.0).BoilerwaterpHof7.0to8.5isrecommended.

Fill the system with water

1. Donotll(exceptforleakagetests)untilboilerisreadytobe

ﬁred.

2. Filltonormalwaterline,halfwayupgaugeglass.

3. Boiler water pH 7.0 to 8.5 is recommended.

4. Followskimmingprocedure,right.

Skimming the boiler

 Cleanallnewlyinstalledsteamboilerstoremove

oil and grease. Failure to properly clean can result

inviolentuctuationsofwaterlevel,waterpassing

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. Provide1½”pipingfromskimtappingtooordrain.

2. Adjustwaterlinetomidpointofskimtapping.SeeFigure3,

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. Feedinwatertomaintainwaterlevel.Cycleburnerstoprevent

rise in steam pressure.

5. Continueskimminguntildischargeisclear.Maytakeseveral

hours.

6. Drain boiler. While boiler is warm, but not hot,ushallinterior

surfacesunderfullpressureuntildrainwaterrunsclear.

7. Removeskimpiping.Plugtapping.

8. Closedraincock.Fillwithfreshwatertowaterline.Start

burnersandsteamfor15minutestoremovedissolvedgases.

Stop burners.

9. Checktrapsandairventsforproperoperation.

10.Process may need to be repeated after several weeks of

operation.

Inspect base insulation

The boiler contains ceramic ﬁber and ﬁberglass

materials.Usecarewhenhandlingthesematerials

perinstructionsonpage25ofthismanual.Failure

to comply could result in severe personal injury.

Checktomakesureinsulationissecureagainstallfoursidesof

thebase.Ifinsulationisdamagedordisplaced,donotoperate

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

Part Number 550-110-738/1012

7 Start-up continued

Operate the boiler

Start the boiler

1. Checkboilerwaterlevel—Shouldbeapproximately½way

up gauge glass.

2. Removeboilerjacketdoorandnotethegasvalvemanufacturer

and model number.

3. FollowtheappropriateOperatingInstructionsfoundintheGSA

SparkIgnitionControlSupplement.(TheOperatingInstruction

labelontheboilerprovidesthesameinformation.)

3. Ifboilerfailstostart,see“Ifboilerdoesn’tstart...Checkfor:”

on this page.

Check system and boiler

 Eliminateallsystemleaks.Continualfreshmakeup

waterwillreduceboilerlife.Mineralscanbuildup

insections,reducingheattransfer,overheatingcast

iron,andcausingsectionfailure.

 Ifyoudiscoverevidenceofanygasleak,shutdown

theboileratonce.Findtheleaksourcewithbubble

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. Checksystempipingforleaks.Iffound,shutdownboilerand

repair immediately.

2. Inspectventsystemthoroughlyforsignsofdeteriorationfrom

corrosion,physicaldamageorsagging.Verifythatmasonry

chimney liners are in good condition, with no obstructions,

and there are no openings into the chimney.

3. Checkaroundtheboilerforgasodorfollowingtheprocedure

of“Checkforgasleaks”,page17.

4. Verifyoperationusingproceduresbelow.Perform“Checkout

procedure”,page20,andllinthe“Installationandservice

certiﬁcate”.

If boiler doesn’t start . . . Check for:

1. Looseconnections,blownfuseorserviceswitchoff?

2. Highlimitswitchsetbelowboilerpressure?

3. Thermostatsetbelowroomtemperature?

4. Gasnotturnedonatmeterorboiler?

5. Incominggaspressurelessthan:

 5”w.c.fornaturalgas?11”w.c.forpropanegas?

6. Ifnoneoftheabovecorrectstheproblem,see“Troubleshoot-

ing”,intheGSASparkIgnitionControlSupplement.

DO NOT proceed with boiler operation unless

boiler and system have been ﬁlled with water

andallinstructionsandproceduresofprevious

manual sections have been completed. Failure to

do so could result in severe personal injury, death

orsubstantialpropertydamage.Beforestartingthe

boiler . . .

• SeeSparkIgnitionControlSupplementforOperat-

ingInstructions

• Verifytheboilerandsystemwaterleveliscorrect(no

morethan½ofgaugeglassorlessthan¼”above

bottomofgaugeglass).

• Verify the“Preparation” procedures, on previous

page, have been completed.

GSA

Gas-Fired Steam Boilers – Boiler Manual

Part Number 550-110-738/1012

7 Start-up continued

Verify operation

Check burner ﬂame — Pilot burner

Proper pilot ﬂame (see Figure 19):

1. Blueame.

2. Innerconeengulngthermocouple.

3. Thermocouple glowing cherry red.

Improper pilot ﬂame:

1. Overf

ired—Largeameliftingorblowingpastthermocouple.

2. Underred —  Small  ame.   Inner cone  not  engulng

thermocouple.

3. Lackofprimaryair—Yellowametip.

4. Incorrectlyheatedthermocouple.

Check burner ﬂame — Main burner

Proper main burner ﬂame (see Figure 20):

1. Yellow‑orangestreaksmayappear(causedbydust).

Improper main burner ﬂame:

1. Overred—Largeames.

2. Underred—Smallames.

3. Lackofprimaryair—Yellowtippingonames(sootingwill

occur).

Figure 19 Typical pilot burner flame

Check vent damper operation

1. Raiseroomthermostattocallforheat—Ventdamperactuator

will slowly open vent damper.

2. Whenventdamperisfullyopen—Maingasvalvewillopen

and main burners will ignite.

 Ventdampermustbefullyopenbeforemainburn-

erslight.Ifventdamperdoesnotfullyopen,ue

products such as carbon monoxide will escape into

house, causing severe personal injury or death.

3. Lowerthermostatsetting—Mainburnerameswillgoout,

then vent damper will close.

4. RepeatSteps1through3severaltimestoverifyoperation.

5. Return thermostat to normal setting.

6. Set thermostat heat anticipator setting indicated on wiring

diagram.

Check venting system operation

Withboilerring,holdacandleormatchbelowloweredgeofdraft

hood“skirt.”Ifamedoesnotblowout,butburnsundisturbed,

theventsystemisworkingproperly.Ifameblowsoutorickers

severely, the ventsystemmustbecheckedfor obstructionsor

othercausesofimproperventing.

Figure 20 Typical main burner flame

GSA

Gas-Fired Steam Boilers – Boiler Manual

Part Number 550-110-738/1012

8 Checkout procedure

 Boilerandheatdistributionunitslledwithwater?

 Boilersproperlyskimmed?

 Airpurgedfromgaspiping?Pipingcheckedforleaks?

 Correctly‑sized manifoldorifices installed? SeeTable3,

page7,tochecksizeandfueltype.

Correctlysizedmanifoldoricesmustbeused.

Failure to do so will cause severe personal injury,

death or substantial property damage.

 Buttononspillswitchpushedin?

 FollowOperatingInstructionsinControlSupplementforproper

start‑up?

 Properburnerameobserved?See“Verifyoperation,”page

19.

Test limit control — While burners are operating, move

indicator on limit control below actual boiler pressure.

Burners shouldgo off. Raise setting onlimit control above

boiler pressure and burners should reignite.

 Testlowwatercutoff—Checkprobe‑typelowwatercutofffor

proper operation.

a. Turnoffpowertoboilerandwait5minutes.

b. Drainwatertobottomofgaugeglass.

c. Turn on power.

d. Setthermostattocallforheat.Redneonlamponlower

watercutoffshouldlight.

e. Wait 5 minutes. Boiler should not ﬁre.

f. Rellboilertocorrectwaterline.Redlampshouldgooff.

g. Wait 5 minutes. Boiler should ﬁre.

h. Return thermostat to normal setting.

Test additional eld‑installed controls —  If  boiler has an

additionalhighlimit, lowwatercutoffor othercontrols,test

foroperationasoutlinedbymanufacturer.Burnersshouldbe

operatingandshouldgooffwhencontrolsaretested.When

controls are restored, burners should reignite.

 Testignitionsystemsafetydevice—

Installation and Service Certiﬁcate

Boilermodel__________________Series__________CPnumber___________Dateinstalled_______________

MeasuredBtuhinput____________

Installer______________________________________________________________________________________

(company) (address) (phone)

_____________________________________

 (installer’ssignature)

o Installationinstructionshavebeenfollowed.

o Check‑outsequencehasbeenperformed.

o Aboveinformationiscertiedtobecorrect.

o Informationreceivedandleftwithowner/maintenanceperson.

Spark ignition boilers:Connectmanometertooutletside

ofgasvalve.Startboiler,allowingfornormalstart‑upcycle

to occur and main burners to ignite. With main burners on,

manually shut off gas supply at manual main shutoff gas

valve.Burnersshouldgooff.Openmanualmainshut‑offgas

valve.Manometershouldconrmthereisnogasow.Pilot

willrelight,amesensingelementwillsensepilotameand

mainburnersreignite.Putboilerbackintooperation.

 Setlimitcontrol(s)tosystempressurerequirements.Adjust

balancing valves and controls to provide design pressure to

system.

 Verifythermostatheatanticipator(ifavailable)setproperly?

See“Thermostat”,page16.

 Cycleboilerwiththermostat—Raisetohighestsettingand

verify boiler goes through normal start‑up cycle. Lower to

lowestsettingandverifyboilergoesoff.

 Measurenaturalgasinput:

a. Operate boiler 10 minutes.

b. Turnoffotherappliances.

c. Atnaturalgasmeter,measuretime(inseconds)required

touseonecubicfootofgas.

d. Calculategasinput:

3600 x 1000

number of seconds from step c

= Btuh

e. Btuh calculated should approximate input rating on boiler

rating label.

 Checkmanifoldgaspressurebyconnectingmanometerto

downstreamtesttappingonmaingasvalve.Manifoldpressure

fornaturalgasshouldbe3.5”w.c.andforpropanegasshould

be 10” w.c.

 Observeseveraloperatingcyclesforproperoperation.

Set room thermostat to desired room temperature.

 Fillin“Installationandservicecerticate”below?

Review all instructions shipped with this boiler with owner or

maintenance person. Return instructions to envelope and give

toownerorplaceinpocketinsidefrontpanelinboiler.

Milwaukee GSA-075 User manual

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