Milwaukee GSA-075 User manual

Milwaukee
Brand
Milwaukee
Model
GSA-075
Category
Water heaters & boilers
Type
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
2
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
3
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
4
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
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
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
6
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
7
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
J
(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
8
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
9
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
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 (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
10
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
11
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
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,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
1
½ 1 ½
3
2
½
GSA-125/150
125 1 ¼ 1 ¼
2
½
2 ¼
Use boiler feed
system
GSA-175
150
1
½ 1 ½
3
2
½
GSA-200
175 1 ¾ 1 ¾
Use boiler feed
system
GSA-250
225
2
½
2
GSA-300
250
2
½
2 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
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
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. 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
15
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
fe
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
16
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
17
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
18
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
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. 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
20
Part Number 550-110-738/1012
8 Checkout procedure
o
Boilerandheatdistributionunitslledwithwater?
o
Boilersproperlyskimmed?
o
Airpurgedfromgaspiping?Pipingcheckedforleaks?
o
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.
o
Buttononspillswitchpushedin?
o
FollowOperatingInstructionsinControlSupplementforproper
start‑up?
o
Properburnerameobserved?See“Verifyoperation,”page
19.
o
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.
o
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.
o
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.
o
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.
o
Setlimitcontrol(s)tosystempressurerequirements.Adjust
balancing valves and controls to provide design pressure to
system.
o
Verifythermostatheatanticipator(ifavailable)setproperly?
See“Thermostat”,page16.
o
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.
o
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.
o
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.
o
Observeseveraloperatingcyclesforproperoperation.
o
Set room thermostat to desired room temperature.
o
Fillin“Installationandservicecerticate”below?
o
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.
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23
  • Page 24 24
  • Page 25 25
  • Page 26 26
  • Page 27 27
  • Page 28 28
  • Page 29 29
  • Page 30 30
  • Page 31 31
  • Page 32 32

Milwaukee GSA-075 User manual

Milwaukee
Brand
Milwaukee
Model
GSA-075
Category
Water heaters & boilers
Type
User manual
Download PDF
report

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI

Other documents