Boiler Manual Gas-Fired Steam Boilers GSAicpindexing.toddsit.com/documents/086477/67001100400.pdf · 6 Field wiring ... Boiler Manual Gas-Fired Steam Boilers Hazards that will or

Part Number 670 01 1004 00

GSA

This manual must only be used by a qualified heating installer/service technician. Failure to comply could result insevere 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 numberfrom the boiler jacket. You may list the CP number in the space provided on the “Installation and service certificate” found onpage 16.

Contents Page

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

2 Prepare boiler ..................................................................... 6

3 Install piping ........................................................................ 9

4 Install controls .................................................................. 11

5 Install gas piping ............................................................... 12

6 Field wiring ....................................................................... 13

7 Start-up ............................................................................ 14

8 Checkout procedure ......................................................... 16

9 Sequence of operation ...................................................... 17

10 Lighting instructions .......................................................... 18

11 Service and maintenance ................................................. 20

12 Troubleshooting ................................................................ 24

13 Replacement parts ........................................................... 26

14 Dimensions ...................................................................... 30

15 Ratings ............................................................................. 31

Boiler Manual

Gas-Fired Steam Boilers

Hazards that will or can cause minor personal injuryor property damage.

Special instructions on installation, operation ormaintenance that are important but not related topersonal injury or property damage.

INSTALLER — Read all instructions beforeinstalling. Read page 2 first. Follow all instructionsin proper order to prevent personal injury or death.

• Consider piping and installation when determiningboiler location.

• Any claims for damage or shortage in shipmentmust be filed immediately against the transportationcompany 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 tocomply could result in severe personal injury, deathor substantial property damage.

• This manual is for use only by your qualifiedheating installer/service technician.

• Please see the User’s Information Manual for yourreference.

• Have the boiler serviced by a qualified servicetechnician, at least annually.

GSA Gas-Fired Steam Boilers – Boiler Manual

32 Part Number 670 01 1004 00

Handling ceramic fiber and fiberglass materials

REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS

The combustion chamber lining or base insulation panels in this product contain ceramic fiber materials. Ceramicfibers can be converted to cristobalite in very high temperature applications. The International Agency for Researchon Cancer (IARC) has concluded, "Crystalline silica inhaled in the form of quartz or cristobalite from occupationalsources is carcinogenic to humans (Group 1).":

■ Avoid breathing dust and contact with skin and eyes.

• Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements forcristobalite at the time this document was written. Other types of respirators may be needed depending onthe job site conditions. Current NIOSH recommendations can be found on the NIOSH web site at http://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators, manufacturers, and phone numbers arealso listed on this web site.

• Wear long-sleeved, loose fitting clothing, gloves, and eye protection.

■ Apply enough water to the combustion chamber lining or base insulation to prevent airborne dust.

■ Remove combustion chamber lining or base insulation from the boiler and place it in a plastic bag for disposal.

■ Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.

NIOSH stated First Aid.■ Eye: Irrigate immediately

■ Breathing: Fresh air.

REMOVAL OF FIBERGLASS WOOL — OR —

INSTALLATION OF FIBERGLASS WOOL, COMBUSTION CHAMBER LINING OR BASEPANELS:

This product contains fiberglass jacket insulation and ceramic fiber materials in combustion chamber lining or basepanels in gas fired products. Airborne fibers from these materials have been listed by the State of California as apossible cause of cancer through inhalation.


• Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements forfiberglass wool at the time this document was written. Other types of respirators may be needed dependingon the job site conditions. Current NIOSH recommendations can be found on the NIOSH web site at http://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators, manufacturers, and phone numbers arealso listed on this web site.


■ Operations such as sawing, blowing, tear out, and spraying may generate airborne fiber concentration requiringadditional protection.





2 Part Number 670 01 1004 00

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 safelighting and other performance criteria when boilerunderwent tests specified in ANSI Z21.13–latestedition.

Before locating the boiler:❏ Check for nearby connection to:

• Venting connections• Gas supply piping• Electrical power

❏ Check area around boiler. Remove any combustible materials,gasoline and other flammable liquids.

Failure to keep boiler area clear and free ofcombustible materials, gasoline and other flammableliquids and vapors can result in severe personalinjury, death or substantial property damage.

❏ Boiler must be installed so that gas control system componentsare protected from dripping or spraying water or rain duringoperation or service.

❏ If new boiler will replace existing boiler, check for and correctsystem problems, such as:1. System leaks causing oxygen corrosion or section cracks

from hard water deposits.

Codes & checklistFailure to adhere to the guidelines below canresult in severe personal injury, death orsubstantial property damage.

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 flow 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 locationexternal to the appliance, if possible.

5. Do not use this boiler if any part has been under water.Immediately call a qualified service technician to inspectthe boiler and to replace any part of the control systemand 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 willoccur, causing leakage between boiler sections, circulatorflanges, diaphragm tanks or other system components.This can result in substantial property damage.

7. DO NOT use "homemade cures" or "boiler patentmedicines". Serious damage to boiler, personnel and/orproperty may result.

8. Continual fresh makeup water will reduce boiler life. Mineralbuildup in sections reduces heat transfer, overheats castiron, and causes section failure. Addition of oxygen andother gases can cause internal corrosion. Leaks in boileror piping must be repaired at once to prevent makeupwater.

9. Do not add cold water to hot boiler. Thermal shock cancause sections to crack.

1 Prepare boiler locationRead this first!


31Part Number 670 01 1004 00

15 Ratings

Notes1. Based on standard test procedures prescribed by the United States Department of

Energy.2. Net I=B=R ratings are based on net installed radiation of sufficient quantity for the

requirements of the building and nothing need be added for normal piping and pickup.Ratings are based on a piping and pickup allowance of 1.333. An additional allowanceshould be made for unusual piping and pickup loads.

3. See information at right for model number suffixes. Letters shown are model numbersuffixes. An “N” after the model number designates natural gas.

4. Contact your International Comfort Products dealer regarding information and partsfor high altitude applications.

DOE

Boilermodel

number

0–2,000feet altitude

2,000–4,500feet altitude

(Canada)

NetI=B=R ratings

Boiler watercontent(gallons)

(to waterline)

DOESeasonalefficiency(% A.F.U.E)

Chimneyand

breechingsize

Input(Btuh)

DOE Heating Capacity(Output) (Btuh)

Input(Btuh)

Output(Btuh)

Sq. Ft.Steam

SteamBtuh

(Note 3) (Note 1) (Note 4) (Note 2) (Note 3)

GSA075 75,000 62,000 67,500 54,000 196 47,000 8.4 81.0 5"I.D. x 20'

GSA100 100,000 83,000 90,000 72,000 258 62,000 8.4 81.3 5"I.D. x 20'

GSA125 125,000 104,000 112,500 90,000 325 78,000 9.8 81.5 6"I.D. x 20'

GSA150 150,000 125,000 135,000 108,000 392 94,000 9.8 81.6 6"I.D. x 20'

GSA175 175,000 145,000 157,500 126,000 454 109,000 11.2 81.9 7"I.D. x 20'

GSA200 200,000 167,000 180,000 144,000 521 125,000 11.2 81.9 7"I.D. x 20'

GSA250 250,000 209,000 225,000 180,000 654 157,000 12.6 82.0 8"I.D. x 20'


3Part Number 670 01 1004 00

Clearances

Flooring and foundationDo not install boiler on combustible flooring orcarpeting even if a concrete or aerated foundation isused. Fire can result, causing severe personal injury,death or substantial property damage.

1. Provide a solid brick or minimum 2-inch thick concretefoundation pad if any of the following is true:• floor can become flooded.• 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 concretefloor of the boiler room.

• Concrete floor is “green”.• Water is channeled under the concrete.

Residential garage installationTake the following special precautions when installing the boiler ina residential garage. If the boiler is located in a residential garage,per ANSI Z223.1, paragraph 5.1.9:• Mount the boiler a minimum of 18 inches above the floor of the

garage to assure the burner and ignition devices will be no lessthan 18 inches above the floor.

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

1 Prepare boiler location continued

Figure 1 Minimum clearances - alcove installation only

Large space — (see minimum room volume, below)If installed in a four-walled room, the room volume must be no lessthan the following (Ceiling height, if over 8 feet, can only be countedas 8 feet.):

GSA075 & GSA100 147 cubic feetGSA125 & GSA150 184 cubic feetGSA175 & GSA200 221 cubic feetGSA250 257 cubic feet

The room must provide the following minimum clearances (in alldirections) to the boiler and components:

Jacket and flue collector sides & rear 6 inchesJacket front 18 inchesVent pipe (other than Type B vent) 6 inchesVent damper 6 inches

Table 1 Minimum foundation size

Service clearances1. Provide minimum clearances for cleaning and servicing the

boiler and for access to controls and components as listed inthe table below.

2. Provide at least screwdriver clearance to jacket front panelscrews for removal of front panel for inspection and minorservice. If unable to provide at least screwdriver clearance,install unions and shutoff valves in system so boiler can bemoved for servicing.

Service clearances: Minimum

Top (for cleaning flueways) 46"Front (for access to controls and components) 18"Back 6"

Left side (for cleaning and servicing) 24"Right side 6"

Minimum clearance to combustible materials

General — all installations1. Hot water pipes must be at least ½" from combustible material.2. Single-wall vent pipe must be at least 6 inches from combustible

material.3. Type B double-wall metal vent pipe — See vent manufacturer’s

recommendation for clearances to combustible material.

Small space — alcove (not closet) installationGSA boilers are not approved for closet installation— only for alcove installation, with minimumclearances as shown in Figure 1 and the table below,and the front side completely open — that is, a 3-walled room.

Clearances from combustible materials: Minimum

Top 46"Front (provide means of access) 3"

Back 6"Left side (provide means of access) 4"Right side 4"

Boilermodel

Minimumfoundation

length

Minimumfoundation

widthGSA075 – GSA100 29 5/8" 19"GSA125 – GSA150 29 5/8" 23 1/4"

GSA175 – GSA200 29 5/8" 27 1/2"GSA250 29 5/8" 31 3/4"


30 Part Number 670 01 1004 00

Figure 20 Dimensional drawing — ALL DIMENSIONS IN INCHES

14 Dimensions

Boilermodelnumber

Supplytapping

(inches NPT)

Returntapping

(inches NPT)

Gas connection& manifold size

(Note 2)(inches NPT)

“ V”Damperheight(inches)

“ D”Vent

diameter(inches)

“ W”Jacketwidth

(inches)

Approximateshippingweight

GSA075 3 2½ 1/2 6 5 17 430

GSA100 3 2½ 1/2 6 5 17 430

GSA125 3 2½ 1/2 61/2 6 21¼ 505

GSA150 3 2½ 1/2 61/2 6 21¼ 505

GSA175 3 2½ 1/2 9 7 25½ 585

GSA200 3 2½ 1/2 9 7 25½ 585

GSA250 3 2½ 3/4 91/2 8 29¾ 660

Note 2: Size gas piping from meter to boiler per local utility requirements.


4 Part Number 670 01 1004 00


Failure to follow all instructions can result in flue gasspillage and carbon monoxide emissions, causingsevere personal injury or death.

When removing boiler from existing common ventsystem:At the time of removal of an existing boiler, the following steps shallbe followed with each appliance remaining connected to the commonventing system placed in operation, while the other appliancesremaining connected to the common venting system are not inoperation.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 deficiencies which could cause an unsafecondition.

c. Test vent system — Insofar as is practical, close all buildingdoors and windows and all doors between the space in whichthe appliances remaining connected to the common ventingsystem are located and other spaces of the building. Turn onclothes dryers and any appliance not connected to the commonventing system. Turn on any exhaust fans, such as range hoodsand 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 thelighting instructions. Adjust thermostat so appliance will operatecontinuously.

e. Test for spillage at draft diverter relief opening after 5 minutesof main burner operation. Use the flame of a match or candle.

f. After it has been determined that each appliance remainingconnected to the common venting system properly vents whentested as outlined above, return doors, windows, exhaust fans,fireplace dampers, and any other gas-burning appliance to theirprevious conditions of use.

Any improper operation of common venting system should becorrected so the installation conforms with the National Fuel GasCode, ANSI Z223.1–latest edition. Correct by resizing to approachthe minimum size as determined using the appropriate tables inPart 11 of that code. Canadian installations must comply with B149.1or B149.2 Installation Code.

Chimney or vent requirements1. Venting must be installed according to Part 7, “Venting of

Do not alter boiler draft diverter or place anyobstruction or non-certified vent damper in breechingor vent system. CSA certification will become void.Flue gas spillage and carbon monoxide emissionswill occur causing severe personal injury or death.

Inspect existing chimney before installing boiler.Failure to clean or replace perforated pipe or tile liningwill cause severe personal injury or death.

Vent systemEquipment”, of National Fuel Gas Code, ANSI Z223.1–latestedition and applicable building codes. Canadian installationsmust 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 pointwhere it passes through a roof of a building, and at least2 feet higher than any portion of a building within a horizontaldistance of 10 feet.

• Type B vents with listed caps may terminate as in Figure 2if no closer than 8 feet from a vertical wall or similarobstruction.

• Otherwise, Type B vents must terminate at least 2 feet abovethe roof penetration and at least 2 feet higher than any portionof a building within 10 feet.

3. A lined chimney is preferred and must be used when requiredby local, state, provincial and national codes, laws, regulationsand ordinances. Vitreous tile linings with joints that preventretention of moisture and linings made of noncorrosive materialsare best. Advice for flue connections and chimney linings canbe obtained from local gas utility. Type B double-wall metal ventpipe 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 ventdamper is vented through this type of chimney, the potentialexists for condensation to occur. Condensation can damage amasonry chimney. Williamson-Thermoflo recommends thefollowing to prevent possible damage.a. Line chimney with corrosion-resistant metal liner such as

AL29-4C® single-wall stainless steel or B-vent. Size linerper 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 toarea of vent outlet on largest appliance plus 50 percent of ventoutlet area of additional appliances.

Figure 2 Terminations with Type B vent fitted withlisted cap, provided vent is at least 8 feetfrom any vertical wall or similar obstruction

The following requirements apply when you removean existing boiler from a vent system shared withother appliances. If the new boiler will not use thecommon vent, you must test (as described below)each remaining appliance — operating by itself — toverify that the vent system operates adequately.


29Part Number 670 01 1004 00

13 Replacement parts continued

Figure 19 Gas controls

Itemnumber

Descript ion Manufac turer Manufac turer’spart number

Internat ionalComfortProducts

part number

Standing pilot — Natural gas components

1 Gas valve, 1/2" x 1/2", GSA075 through GSA175

Gas valve, 3/4" x 3/4", GSA200 and GSA250

HoneywellRobertshawHoneywell

VR8200A21167200ER

VR8300C4050

511044360WT

511044256WT

2 Pilot assembly kit with orifice International Comfort Products 510811640WT

3 Tubing, pilot, aluminum with fittings 560742860WT

4 Tubing, thermocouple 511724254WT

5 Transformer with receptacle HoneywellWhite-Rodgers

R8285K1004S84A-85

510312166WT

notshown

Wiring harness 591391867WT


5Part Number 670 01 1004 00

Table 2 Corrosive contaminants and likely locations

To prevent potential of severe personal injury or death,check for products or areas listed below beforeinstalling boiler. If any of these contaminants are found:

• Remove contaminants permanently.— OR —

• Isolate boiler and provide outside combustion air. Seenational, provincial or local codes for furtherinformation.

Please review the following information on potential combustion aircontamination problems.See Table 2 for products and areas which may cause contaminatedcombustion air.

Air contamination Air openings

Products to avoid

Spray cans containing chloro/fluorocarbons

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 refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops


Combustion air and ventilation openings must comply with Section5.3, “Air for Combustion and Ventilation”, of National Fuel Gas CodeANSI Z223.1–latest edition, or applicable local building codes.Canadian installations must comply with B149.1 or B149.2Installation Codes.See table below for minimum combustion/ventilation air openingsizes. Where openings are required, provide two (2) openings —one within 12 inches of the ceiling, the other within 12 inches of thefloor, as shown in the table illustrations.

Provide adequate combustion and ventilation air toassure proper combustion and reduce the risk ofsevere personal injury, death or substantial propertydamage caused by flue gas spillage and carbonmonoxide emissions.


28 Part Number 670 01 1004 00

Figure 18 Controls and trim


Itemnumber

Description Manufacturer Manufacturer’spart number

InternationalComfort Products

part number

1 Pressure relief valve, ASME, 15 PSIG, ¾" npt(Fittings shown are factory-installed on boiler.Coupling ¾" npt, Nipple ¾" npt)

ConbracoWatts

13-501-08315

511548023WT

2 Low water cutoff, probe-type Hydrolevel 400 511114515WT

3 Limit control/gauge assembly, includes:Pressure controlGauge, steamSiphon, ¼" npt, 90° brassNipple, close ¼" nptTee, ¼" npt

HoneywellWinter’s

PA-404-AE1437

510312135WT510218045WTobtain locallyobtain locallyobtain locally

4 Gauge glass assembly, includes:Gauge glassGauge glass guard, 9 3/8"Gauge cock set, brass Conbraco

United Brass Wks21-205-03-W905 and 946

591419185WT563334580WT510218145WT

5 Drain valve, ¾" International Comfort Products 511210423WT


6 Part Number 670 01 1004 00

Air openings continued

2 Prepare boiler

Placement and setup

Place boiler/crate near position1. 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.

Inspect orifices and burners1. Remove front jacket door. Remove base access panel (see

Figure 16, item 14, page 26).2. Check for correctly-sized manifold orifices. See Table 3 for sizing.

(The orifice size is stamped on the orifice spud barrel.)Correctly-sized manifold orifices must be used. Failureto do so will result in severe personal injury, death orsubstantial property damage.

3. Level and straighten burners.Burners must be properly seated in slots in burnerrest with their openings face up. Main burner orificesmust inject down center of burner. Failure to properlyseat burners will result in severe personal injury,death or substantial property damage.

4. Reinstall base access panel.Do not operate boiler without access panel securedin place. Failure to comply could cause momentaryflame rollout on ignition of main flame, resulting inpossible fire or personal injury hazard.


Exhaust fans and air moversThe appliance space must never be under a negative pressure.Always provide air openings sized not only to the dimensionsrequired for the firing rate of all appliances, but also to handle the airmovement rate of the exhaust fans or air movers using air from thebuilding or space.

Motorized air dampersIf the air openings are fitted with motorized dampers, electricallyinterlock the damper to:• Prevent the boiler from firing 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 thedamper open) in series with the thermostat input to the boiler. Theboiler will not start if this damper is closed, and will shut down shoulddamper close during operation.

Table 3 Manifold orifice sizing

Pressure test

Perform hydrostatic pressure testPressure test boiler before attaching water or gas piping or electricalsupply.

Prepare boiler for test1. Plug tappings or openings.2. Do not use gauge supplied with boiler for pressure testing. Install

gauge with appropriate range.

Fill and pressure test1. Fill boiler with water. Vent all air. Test boilers between 45-50 psi.

Do not leave boiler unattended. A cold water fill couldexpand and cause excessive pressure resulting insevere personal injury, death or substantial propertydamage.

2. Check for maintained gauge pressure for more than 10 minutes.Visually check for leaks if gauge pressure drops.

Location Natural gas

U. S.Sea level – 2,000 ft over 2,000 ft

2.45 mm (Note 1)

CanadaSea level – 2,000 ft 2,000 – 4,500

2.45 mm 2.30 mmNote 1: For U. S. elevations above 2,000 feet, contact your Williamson-

Thermoflo supplier for details.


27Part Number 670 01 1004 00

Figure 17 Jacket assembly


Item number Description International Comfort Productspart number

1 Jacket panel, left side 421800150WT

2 Jacket panel, top GSA075 & GSA100GSA125 & GSA150GSA175 & GSA200GSA250

421800152WT421800153WT421800154WT421800155WT

3 Jacket panel, right side 421800151WT

4 Jacket panel, door GSA075 & GSA100GSA125 & GSA150GSA175 & GSA200GSA250

421800167WT421800168WT421800169WT421800170WT

5 Jacket panel, interior GSA075 & GSA100GSA125 & GSA150GSA175 & GSA200GSA250

421800162WT421800163WT421800164WT421800165WT

6 Jacket panel, rear GSA075 & GSA100GSA125 & GSA150GSA175 & GSA200GSA250

421800157WT421800158WT421800159WT421800160WT

7 Bottom cross tie GSA075 & GSA100GSA125 & GSA150GSA175 & GSA200GSA250

421800172WT421800173WT421800174WT421800175WT

8 Junction box, 4 x 4 (Available at local supply house)


7Part Number 670 01 1004 00

2 Prepare boiler continued

Pressure test continued Draft diverter & spill switch

Draft diverter installation1. Secure draft diverter to flue collector hood with sheet metal

screws. See Figure 16, items 1 and 9, on page 26. Use boilercement to provide gas tight seal.

Failure to maintain gas-tight seal can cause flue gasspillage and carbon monoxide emissions, resultingin severe personal injury or death.Do not alter boiler draft diverter or place anyobstruction or non-approved vent damper inbreeching or vent system. CSA certification willbecome void. Flue gas spillage and carbon monoxideemissions will occur causing severe personal injuryor death.

Spill switch installation1. Fasten spill switch to draft diverter as shown in Figure 16, item

20, page 26.2. See Wiring diagram on page 17 to connect wires.

Install vent piping1. Connect from draft diverter or vent damper outlet to chimney or

vent with same size vent connector.

2. Where possible, vertical venting to the outside from the draftdiverter or vent damper outlet will offer best performance.

3. Where horizontal vent connector is used, slope upward at least¼" per lineal foot toward chimney or vent and support withhangers to prevent sagging.

4. Breeching must not be connected to any portion of a mechanicaldraft system that can operate under positive pressure.

Long horizontal vent connector, excessive numberof elbow or tees, or other obstructions that restrictthe flow of combustion gases should be avoided.Severe personal injury, death or substantial propertydamage could result.

Drain and remove fittings1. Drain boiler and repair leaks if found.

Leaks must be repaired at once. Failure to do so candamage boiler, resulting in substantial propertydamage.Do not use petroleum based cleaning or sealingcompounds in boiler system. Severe damage to boilerwill 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, below.

Table 4 Control tapping

Figure 3 Control tapping locations

Float-type low water cutoff — If field installing a float-type low water cutoff, it must be piped only to thegauge glass tappings, items H, Figure 3. The tappingsare spaced 9" on center. Use only float-type low watercutoffs with quick-connect hookups that will providea low water cutoff point no higher than 2" above thecenter of the bottom tapping. See page 11, Figure 9,for a typical installation.

Location Size DescriptionC ¾" Probe-type low 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)

3/8" Try cock tappings

L ¼"Siphon, pressure gauge, high limit control

S 1½" Skim tapping

Note: Available only on special request.


26 Part Number 670 01 1004 00

Figure 16 Section assembly, flue collector, draft diverter, vent damper and base assembly

13 Replacement parts

Itemnumber

Description InternationalComfortProducts

part number1 Draft diverter GSA075

GSA100GSA125GSA150GSA175GSA200GSA250

450021285WT450021286WT450021287WT450021288WT450021289WT450021290WT450021291WT

Base insulation kit: Consists of items 3 and 13. 510811660WT2 End section, left hand, 1813 311800007WT3 Back base panel insulation (in Base insulation kit)4 Back base panel GSA075 & GSA100

GSA125 & GSA150GSA175 & GSA200GSA250

451800010WT451800011WT451800012WT451800013WT

5 Back base channel GSA075 & GSA100GSA125 & GSA150GSA175 & GSA200GSA250

451800020WT451800021WT451800022WT451800023WT

6 Front base panel GSA075 & GSA100GSA125 & GSA150GSA175 & GSA200GSA250

451800000WT451800001WT451800002WT451800003WT

7 Back burner support GSA075GSA100GSA125GSA150GSA175GSA200GSA250

451800085WT451800086WT451800087WT451800088WT451800089WT451800090WT451800092WT

8 Burner pan side rail 451800070WT9 Collector hood GSA075 & GSA100


450014733WT450014734WT450014735WT450014736WT

Section replacement kit (Consists of: cope sealand 1 each 3" and 6" square cut seals)

381800100WT

Itemnumber


part number10 End section, right hand, 18118 311800029WT11 Intermediate section, 1815 311800010WT12 Tie rod, 1/2" GSA075 & GSA100


560234470WT560234475WT560234480WT560234485WT

13 Front base panel insulation (in Base insulation kit)14 Base access panel GSA075 & GSA100

GSA125 & GSA150GSA175GSA200GSA250

451800040WT451800041WT451800039WT451800042WT451800043WT

15 Burner with pilot bracket 512200021WT16 Gas valve — see “Gas controls” table on page 2917 Main burner orifice 560528987WT18 Burner manifold GSA075


591125533WT591125538WT591125534WT591125539WT591125535WT591125540WT591125541WT

19 Pilot burner assembly — see “Gas controls” table on page 2920 Spill switch 510350100WT21 Rollout thermal fuse element 512050230WT22 Vent damper 5"

6"7"8"

381800466WT381800467WT381800468WT381800469WT

23 Vent damper actuator only with ventdamper above

24 Vent damper harness 591391795WT


8 Part Number 670 01 1004 00

4. Read and apply the harness plug warning label (shown above)so that it is visible after installation

5. Plug damper harness receptacle into damper harness plug.Bypassing (jumpering) vent damper will cause flueproducts such as carbon monoxide to escape intothe house. This will cause severe personal injury ordeath.After boiler has operated once, if either end of harnessis disconnected, the system safety shutdown willoccur. The boiler will not operate until harness isreconnected.Effikal damper — Damper hold open switch must bein Automatic Operation position for system to operateproperly.


Figure 4 Vent damper assemblies

Vent damperThese systems are used on gas-fired boilers withvent dampers as shipped from factory. Boiler will notoperate without vent damper installed.

Damper bladeSee vent manufacturer’s instructions to install plug (shipped withdamper) in damper hole. Install plug with 3/8" diameter hole in ventdamper hole.

Minimum clearancesProvide a minimum of 6" between the vent damper and anycombustible material. (See “Minimum clearance to combustiblematerials,” page 3, for minimum clearance from jacket top to ceilingto maintain this dimension.)

Damper installationDo not modify draft diverter or vent damper, or makeanother connection between draft diverter and ventdamper or boiler except as noted below. This will voidCSA certification and will not be covered byWilliamson-Thermoflo warranty. Any changes willcause severe personal injury, death or substantialproperty damage.

1. Install vent damper as shown in vent damper manufacturer’sinstructions. Vent damper must be installed so that it servesonly one boiler and so damper blade indicator is visible to theuser. See Figure 4.

2. Screws or rivets used to secure the vent damper to the draftdiverter must not interfere with rotation of the damper blade.

3. Install damper harness between damper actuator and knockoutin jacket top panel. Use strain relief connectors and locknuts tosecure both ends of damper harness.

Keep wiring harness clear of all hot surfaces. Wireinsulation could be damaged, causing risk of electricalshort-circuit.


25Part Number 670 01 1004 00

Is 24VAC present across transformer terminals C & Y?

Is damper harness securely plugged in at both ends?Secure connections.

Check for open thermostat, LWCO, high limit, spill switch orrollout thermal fuse element contacts or check for loosewire connections.

If LWCO, spill switch or rollout thermal fuseelement contacts are open, determine causeand correct condition. Failure to do so willcause severe personal injury, death orsubstantial property damage.

Check/repair out of round stack section. Does vent damperrotate open?

Is 24VAC present across transformer terminal C and yellowwire on vent damper connector?

Is 24VAC present across gas valve terminals?

Open thermostat contacts for 30 seconds. Vent damper willrotate to closed position. Close thermostat contacts. Ventdamper will rotate to open position. Is 24VAC presentacross gas valve terminals?

Remove damper harness fromdamper harness plug.TEMPORARILY install jumperbetween terminal 2 andterminal 5 on damper plug inboiler wiring harness. SeeTable, right. Does boiler fire?

No Yes

No Yes

Chart 1 — Standing pilot — Boiler will not fire

Check for loose wire connections or bad relay ontransformer.

No Yes

Is vent damper rotated open?

No Yes

No Yes

Replace actuator.Retest.

Check continuity of each wire in damper harness. Doescontinuity exist for each wire? See Table right.

Replace damperwiring harness.Retest.

Replace gas valve.Retest.

Is main flame on now?

No Yes

Retest

No Yes

No Yes

No Yes

No Yes

Replace damperactuator. Retest.

Turn gas valve cock toON position. Retest.

Replace gas valve.Retest

Is gas valve cock turned to ON position?

No Yes

Before proceeding, follow "Troubleshooting sequence" on page 24. If problem persists, then:

12 Troubleshooting continued


9Part Number 670 01 1004 00

General

3 Install piping

1. Pipe before installing controls. Connect return piping after jacketis attached. Connect supply piping before or after jacket isattached.

Failure to properly pipe the boiler may result inimproper operation and damage to the boiler orbuilding.

2. See Figure 5 and Table 5. Pipe exactly as shown. Satisfactoryoperation of a steam heating system depends on adequatecondensate return to boiler to maintain a steady water level.Avoid adding raw makeup water. Where condensate return isnot adequate, install low water cutoff/pump control, condensatereceiver and condensate boiler feed pump. Refer to Table 7,page 10, for sizing. See page 7, Table 4, for tapping locations.

Table 5 Recommended pipe sizing

Figure 5 Recommended piping, piping for parallel-flow systems only.

Connecting to counterflow pipingApply the recommended piping in Figures 4 through 7 only whenconnecting to a parallel-flow system. When connecting to acounterflow system, the boiler steam supply must connect into thetop of the counterflow system header, as shown in Figure 6.

Figure 6 Connection to counterflow steam piping

Relief valveInstall relief valve in tapping on top of boiler. See Table 4, page 7,for control tapping locations. See the tag attached to the relief valvefor manufacturer’s instructions.

Follow the steps below to avoid potential severepersonal injury, death or substantial property damage.

• When installing the relief valve, ensure that allconnections, including the valve inlet, are clean andfree from any foreign matter.

• Mount the relief valve only in the vertical position,directly connected to the tapping designated in themanual on top of the boiler.

• Use pipe compound sparingly, or tape, on externalthreads only.

• Do not use a pipe wrench! Use proper type and sizewrench on wrench pads only.

Boiler model number Riser (A) Header (H)see Note

Equalizer (J)

GSA075 and GSA100 2" 2" 1½"

GSA125 through GSA175 2½" 2 ½" 1½"

GSA200 and GSA250 3" 3" 1½"

Note: 24" minimum from waterline to header.


24 Part Number 670 01 1004 00

12 Troubleshooting

Verify proper operation after servicing. • See ventdamper manufacturer’s instructions packed with ventdamper for additional information. Failure to complycould result in severe personal injury, death orsubstantial property damage.

Figure 15 Manually opening vent damper

Label all wires prior to disconnection when servicingcontrols. Wiring errors can cause improper anddangerous operation.Never jumper (bypass) rollout thermal fuse elementor any other device except for momentary testing asoutlined in “Chart 1”, page 25. Severe personal injury,death or substantial property damage can result.Burner base access panel must be in position duringboiler operation to prevent momentary flame rollouton ignition of main flame. Severe personal injury orsubstantial property damage will result.

Before troubleshooting:1. Have the following items:

a. Voltmeter that can check 120 VAC and 24 VAC.b. Continuity checker.c. U-tube manometer.

2. Check for 120 VAC (minimum 102 VAC to maximum 132 VAC)to boiler.

3. Make sure thermostat is calling for heat and contacts (includingappropriate zone controls) are closed. Check for 24 VACbetween thermostat wire nuts and ground.

Troubleshooting sequence:1. Before proceeding, check for:

• Loose connections, blown fuse or service switch off?• High limit switch set below boiler water temperature?• Thermostat set below room temperature?• Gas not turned on at meter or boiler?• Incoming gas pressure less than:

5" w.c. for natural gas? 11" w.c. for propane gas?2. If all of the above check correctly, check gas pressures:

a. With boiler off:• 13" w.c. maximum natural or propane gas pressure

upstream of gas valve.b. With boiler on:

• 5" w.c. minimum natural gas pressure or 11" w.c.propane gas pressure upstream of gas valve.

• 3.5" w.c. minimum natural gas pressure or 10" w.c.propane gas pressure downstream tapping on gasvalve — Can be adjusted by regulator on gas valve.

c. If gas pressure is incorrect or gas is not available to boiler,contact gas supplier to correct before proceeding further.

3. Check pilot operation — Follow “Lighting Instructions”, pages18 and 19.• If gas is available and you cannot obtain a pilot flame, try

purging the gas line and cleaning pilot and pilot gas tubing.Follow “Lighting Instructions” again. If you still cannot obtaina flame, replace pilot burner and gas tubing. If this does notallow you to obtain a pilot flame, replace gas valve.

• If you obtain a pilot flame, but pilot will not remain on, replacethermocouple. If this does not correct problem, replace gasvalve and pilot burner.

• If pilot stays on, but main gas will not come on, proceed topage 25.

In event of vent damper failure:

Effikal vent damperIf troubleshooting chart recommends replacing actuator and actuatoris not immediately available, damper blade can be fixed in an openposition to allow boiler operation. Manually turning blade can causeactuator damage. Follow these instructions only in case of no heator damper actuator malfunction.1. Move damper service switch to Hold Damper Open position.

Apply call for heat to boiler. Damper blade should then rotate toOpen position and boiler will fire.

2. If step 1 does not open damper, manually rotate damper bladeto open position using wrench or pliers on flat shaft betweendamper and actuator. Boiler will fire. Verify that damper serviceswitch is in Hold Damper Open position. See Figure 15.

3. Do not leave vent damper permanently in this position. Replaceactuator immediately. If vent damper is left in Open position,boiler will not operate at published efficiencies.

Johnson Controls vent damperIf troubleshooting chart recommends replacing actuator and actuatoris not immediately available, damper blade can be fixed in an openposition to allow boiler operation. Follow these instructions only incase of no heat or damper actuator malfunction. See Figure 15.1. Turn off power to boiler.

Failure to turn off power to boiler can result in severepersonal injury, death or substantial property damage.

2. See vent damper manufacturer’s instructions for procedure tofix vent damper in open position.

3. Turn on power to boiler.4. Using wrench or pliers on flat shaft section, manually rotate

damper blade until green light turns on. Boiler will fire. SeeFigure 15.



10 Part Number 670 01 1004 00

3 Install piping continued

Modern steam boilers are designed to steam for less time thanolder, larger boilers. When replacing an older steam boiler the systemcondensate return time may be longer than the steaming time. Thiscould cause the following problems:1. Boilers fitted with an automatic water feed could overfill.2. Units fitted 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 areservoir pipe is required to lengthen steaming time for a residentialinstallation: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 tothe 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 morethan 10 minutes, a reservoir pipe (or boiler feed system) isrecommended. See Table 6, this page, for suggested reservoir pipesize. Install as shown in Figure 7, below.For larger systems (as noted in Table 6), use a boiler feed systemwith a condensate tank and feed pump. You will have to install a lowwater cutoff/pump control on the boiler to operate the pump. UseTable 7 to size boiler feed systems. See page 7, Table 4, for tappinglocations. (The use of a combination condensate tank and float-controlled condensate return pump is not recommended.)For most residential installations a reservoir pipe may be all that isnecessary to ensure proper operation.

Condensate return

Figure 7 Recommended piping for parallel-flowsystems with optional reservoir pipe

During operation, this valve may discharge largeamounts of steam and/or hot water. Therefore, toreduce the potential for bodily injury and propertydamage, a discharge line MUST be installed that:

• Is connected from the outlet to a safe point ofdischarge with no intervening valve.

• Allows complete drainage of both the valve and thedischarge line.

• Is independently supported and securely anchoredso as to avoid applied stress as possible.

• Terminates freely to atmosphere where anydischarge will be clearly visible and is at no risk offreezing.

• Is, over its entire length, of a pipe size equal to orgreater than that of the valve outlet.Use only schedule 40 metal pipe for discharge. (Donot use schedule 80, extra strong or double strongpipe or connections.) DO NOT CAP, PLUG OROTHERWISE OBSTRUCT DISCHARGE PIPEOUTLET! If discharge is piped upward, a condensatedrain must be provided in the elbow below the verticalpipe to prevent condensate from returning into thevalve. Failure to comply with these instructions willcause a dangerous spray of hot water and steamthat would cause severe personal injury or death.

Relief valve continued

Table 7 Boiler feed system sizing

Table 6 Reservoir pipe sizingBoilermodelnumber

Boilergrossoutput

Time from initial steaming to average condensatereturn (boiler steaming capacity based on 970 Btu per

pound of steam)15 minutes 20 minutes 30 minutes

MBH gallonspipe

length(feet)

gallonspipe

length(feet)

gallonspipe

length(feet)

GSA075 75 1 1 1½ 1½Use boiler feed

systemGSA100 100 1 1 2 2GSA125 125 1¼ 1¼ 2½ 2¼GSA150 150 1½ 1½ 3 2½GSA175 175 1¾ 1¾

Use boiler feed systemGSA200 200 2 2

GSA250 250 2½ 2¼Designed full capacity steaming time of modern boilers is 10 minutes.

Boilermodelnumber

I=B=Rgrossoutput(poundssteam

per hour)

Conden-sate

(gallonsper hour)

Minimum condensate receivercapacity gallons for boiler

steaming times (minutes) of:(note 1)

Suggestedfeed pumpcapacity(GPM @15 PSI)(note 2)

15 min. 30 min. 45 min. 60 min.

GSA075 63 8 2 4 6 8 0.2

GSA100 81 10 3 6 9 12 0.3

GSA125 102 12 4 7 11 14 0.4

GSA150 122 15 5 9 14 18 0.5

GSA175 142 17 5 10 15 20 0.6

GSA200 163 20 6 12 18 24 0.7

GSA250 203 24 7 14 22 29 0.8

Notes1. Maximum time to when condensate returns to boiler.2. If pump capacity exceeds capacity shown, pump can be throttled with globe or

ball valve.


23Part Number 670 01 1004 00

❏❏❏❏❏ Check/test. . . . . . . . . .Boiler relief valve1. After following the warning directions below, if the relief valve

weeps or will not seat properly, replace the relief valve.Before testing, make certain discharge pipe is properlyconnected to valve outlet and arranged to containand safely dispose of boiler discharge. Wear glovesto protect your hands from hot surfaces. Verify thatdischarge piping is installed in accordance with thismanual and the instructions on the relief valve tag.Failure to comply will expose operator and others tosevere personal injury or death.Safety relief valves should be reinspected AT LEASTONCE EVERY THREE YEARS, by a licensedplumbing contractor or authorized inspection agency,to ensure that the product has not been affected bycorrosive water conditions and to ensure that thevalve and discharge line have not been altered ortampered with illegally. Certain naturally occurringconditions may corrode the valve or its componentsover time, rendering the valve inoperative. Suchconditions are not detectable unless the valve andits components are physically removed andinspected. This inspection must only be conductedby a plumbing contractor or authorized inspectionagency — not by the owner. Failure to reinspect theboiler relief valve as directed could result in unsafepressure buildup, which can result in severe personalinjury, death or substantial property damage.Check the setting of the boiler limit control. The controlshould never be set with a pressure above 10 psig.Operating at a higher pressure can cause damageto the boiler relief valve.The boiler relief valve must be tested at least monthlyduring the heating season to verify the valve anddischarge piping flow freely. If corrosion and/ordeposits are noticed within the valve body, testingmust be performed more often. A “try lever test” mustalso be performed at the end of any non-serviceperiod. Follow the instructions below for a “try levertest”:

• With the system at operating pressure, lift and holdthe test lever fully open for at least 5 seconds to flushthe valve seat free of sediment and debris. Thenrelease lever and permit the valve to snap shut.

❏❏❏❏❏ Review with owner1. Review the User’s Information Manual with the owner.2. Emphasize the need to perform the maintenance schedule

specified in the User’s Information Manual (and in this manualas well).

3. Remind the owner of the need to call in a licensed contractorshould the boiler or system exhibit any unusual behavior.

4. Remind the owner to follow the proper shutdown procedureand to schedule an annual start-up at the beginning of the nextheating season.

The boiler contains ceramic fiber and fiberglassmaterials. Use care when handling these materialsper instructions on page 32 of this manual. Failure tocomply could result in severe personal injury.

1. Shut down boiler — Follow “To Turn Off Gas to Appliance”instructions on boiler and “Lighting Instructions”.

2. Disconnect breeching and remove damper and draft diverter.3. Remove upper rear jacket panel. Turn back jacket insulation to

expose collector hood.4. Remove collector hood. Clean excess boiler cement from

collector hood and cast iron sections.5. Remove burners from base of boiler. Follow “Burners and base”

on page 21, to thoroughly clean burners. Place newspaper inbase of boiler to collect soot that will fall.

6. With a wire flue brush, clean between the sections.7. Remove paper and soot. Vacuum or brush base and

surrounding area.8. Replace collector hood. Seal with boiler cement.

❏❏❏❏❏ Cleaning boiler heating surfaces

11 Service and maintenance continued


11Part Number 670 01 1004 00

Figure 8 Controls

4 Install controls

Figure 9 Float-type low water cutoff(when provided by others)

Float-type low water cutoff (when provided by others)1. Install low water cutoff as shown in Figure 9, 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 floor close to floor drain toeliminate potential of severe burns. Do not plug, valveor place any obstruction in blowdown line.

3. Water feeders are not recommended for primary control. A lowwater cutoff with pump controller is recommended with acondensate receiver and feed pump.

ControlsFailure to properly install, pipe and wire boiler controlsmay result in severe damage to the boiler, buildingand personnel.

1. Controls are mounted and wired as shown in Figure 8. for actualtapping 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 on page 17.


22 Part Number 670 01 1004 00


Gas piping1. Sniff near floor and around boiler area for any indication of a

gas leak.2. Test gas piping using bubble test, per page 12 of this manual, if

there is any indication of a leak.

Boiler waterlineNormal waterline is halfway up gauge glass.

Limit controls1. Inspect and test the boiler limit control. Verify operation by turning

control set point below boiler pressure. Boiler should cycle off.Return dial to original setting.

Gauge glassNormal waterline is halfway up gauge glass. Clean when needed.1. Close lower gauge cock.2. Open pet cock.3. Open lower gauge cock and allow a small amount of water to

flush out through open pet cock.4. Close pet cock.5. Open lower gauge cock.

Boiler pressure must be low to eliminate potential ofsevere burns.If gauge glass breaks, close bot gauge cocks.Replace gauge glass. Do not replace with thin glasstubing. Failure to comply could cause severe personalinjury, death or substantial property damage.

❏❏❏❏❏ Service. . . . . . . . . . ❏❏❏❏❏ Check/test. . . . . . . . . .

❏❏❏❏❏ Start-up. . . . . . . . . .

1. Perform “Start-up” procedures, Section 7, pages 14-15, including“Verify operation” of burners and vent damper on page 15.

2. Check gas piping, per pages 12 and 14, verifying no indicationsof leakage and all piping and connections are in good condition.

3. Read the “Lighting Instructions” (page 18 or 19, whicheverapplies based on boiler gas valve).

4. Start the boiler following the “Lighting Instructions”, page 18or 19.

❏❏❏❏❏ Check/test. . . . . . . . . .

Low water cutoffs

Probe-type low water cutoff (see below)Clean probe-type low water cutoff for proper operation.1. Turn off power to boiler and wait 5 minutes.2. Drain water to bottom of gauge glass.3. Turn on power.4. Set thermostat to call for heat. Red neon lamp on lower water

cutoff should light.5. Wait 5 minutes. Boiler should not fire.6. Refill boiler to correct waterline. Red lamp should go off.7. Wait 5 minutes. Boiler should fire.8. Return thermostat to normal setting.

Float-type low water cutoff (when provided by others— see below)Clean float-type low water cutoff (when provided by others) to clearfloat chamber of sediment.1. Open blowdown valve at bottom control.2. Drain water into a bucket.

Scald potential. Boiler pressure must be low to avoidthe potential of severe burns from steam.

3. Check float-type low water cutoff for proper operation:a. Turn operating control to call for heat.b. Before water gets hot, drain to bottom of gauge glass. Boiler

should shut off after water level lowers a few inches.c. Refill boiler to correct waterline. Boiler should come back

on.


12 Part Number 670 01 1004 00

Table 8 Pipe capacity for 0.60 specific gravity natural gas

5 Install gas piping

Natural Gas:1. See Table 8 for pipe length and diameter. Base on rated

boiler input, found on page 31 (divide by 1,000 to obtaincubic feet per hour). Table 8 is only for gas with specific gravity0.60, with a pressure drop through the gas piping of 0.30"w.c. For additional gas pipe sizing information, see ANSIZ223.1 (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 ifinlet 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.

1. Remove jacket front panel and see Figure 10 to pipe gas toboiler.a. Install drip leg at inlet of gas connection to boiler. Where

local utility requires drip leg to be extended to the floor, useappropriate 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 utilityrequirements.

d. In Canada — When using manual main shutoff valve, it mustbe 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 flame —Use bubble test. Failure to use bubble test or checkfor gas leaks can cause severe personal injury, deathor substantial property damage.

5. Use pipe dope compatible with propane gases. Apply sparinglyonly to male threads of pipe joints so that pipe dope does notblock gas flow.

Failure to apply pipe dope as described in this manualcan result in severe personal injury, death orsubstantial property damage.

Connecting gas supply piping to boiler

Gas pipe

length(feet)

Capacity of pipe for pipe size of:(Capacity in standard 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

Figure 10 Gas supply piping


21Part Number 670 01 1004 00

The boiler should be inspected and started annually,at the beginning of the heating season, only by aqualified service technician. In addition, themaintenance and care of the boiler designated in Table9, page 20 and explained on the following pages mustbe performed to assure maximum boiler efficiencyand reliability. Failure to service and maintain the boilerand system could result in equipment failure.Electrical shock hazard — Turn off power to the boilerbefore any service operation on the boiler except asnoted otherwise in this manual. Failure to turn offelectrical power could result in electrical shock,causing severe personal injury or death.The boiler contains ceramic fiber and fiberglassmaterials. Use care when handling these materialsper instructions on page 32 of this manual. Failure tocomply could result in severe personal injury.

❏❏❏❏❏ Inspect . . . . . . . . . .Reported problemsInspect any problems reported by owner and correct beforeproceeding.

Boiler area1. Verify that boiler area is free of any combustible materials,

gasoline and other flammable vapors and liquids.2. Verify that boiler area is free of any of the contaminants listed in

Table 2 on page 5 of this manual. If any of these are present inthe boiler intake air vicinity, they must be removed. If they cannotbe removed, install combustion air piping to the boiler inaccordance with national, provincial or local codes.

Air openings1. Verify that combustion and ventilation air openings to the boiler

room and/or building are open and unobstructed. Checkoperation and wiring of automatic combustion air dampers, ifused.

2. Verify that boiler vent discharge and air intake are clean andfree of obstructions.

Flue gas vent system1. Visually inspect entire flue gas venting system for blockage,

deterioration or leakage. Repair any joints that show signs ofleakage in accordance with vent manufacturer’s instructions.

2. Verify that masonry chimneys are lined, lining is in goodcondition, and there are not openings into the chimney.

Failure to inspect for the above conditions and havethem repaired can result in severe personal injury ordeath.

Pilot and main burner flames1. Visually inspect pilot burner and main burner flames as directed

under Section 7, page 15 of this manual.

Piping1. Check the boiler interior piping and all system piping for signs

of leaks.2. Repair any leaks before proceeding.

Do not use petroleum-based cleaning or sealingcompounds in boiler system. Severe damage to boilerwill occur, resulting in substantial property damage.

Eliminate all system or boiler leaks. Continual freshmakeup water will reduce boiler life. Minerals canbuild up in sections, reducing heat transfer,overheating cast iron, and causing section failure.Leaking water may also cause severe propertydamage.

Boiler heating surfaces1. Disconnect the vent pipe at the boiler draft diverter and remove

draft diverter after turning off power to the boiler.2. Use a bright light to inspect the boiler flue collector and heating

surfaces.3. If the vent pipe or boiler interior surfaces show evidence of

soot, follow “Cleaning boiler heating surfaces”, page 23. Removethe flue collector and clean the boiler if necessary after closerinspection of boiler heating surfaces.

4. If there is evidence of rusty scale deposits on boiler surfaces,check the water piping and control system to make sure theboiler return water temperature is properly maintained (per thismanual).

5. Reconnect vent and draft diverter. Replace all boiler componentsbefore returning to service.

6. Check inside and around boiler for evidence of any leaks fromthe boiler. If found, locate source of leaks and repair.

Burners and base1. After turning off power to the boiler, remove the jacket door and

base access panel (Figure 16, item 4, page 26).2. Inspect burners and all other components in the boiler base.3. If burners must be cleaned, raise rear of each burner to release

from support slot, slide forward and remove. Then brush andvacuum the burners thoroughly, making sure all ports are freeof debris. Carefully replace all burners, making sure burner withpilot bracket is replaced in its original position and all burnersare upright (ports up).

4. Inspect the base insulation.The boiler contains ceramic fiber and fiberglassmaterials. Use care when handling these materialsper instructions on page 32 of this manual. Failure tocomply could result in severe personal injury.

a. Verify that the insulation is intact and secure against all foursides of the base.

If insulation is damaged or displaced, do not operatethe boiler. Replace or reposition insulation asnecessary. Failure to replace damaged insulation canresult in a fire hazard, causing severe personal injury,death or substantial property damage.

❏❏❏❏❏ Inspect . . . . . . . . . .



13Part Number 670 01 1004 00

For your safety, turn off electrical power supply atservice entrance panel before making any electricalconnections to avoid possible electric shock hazard.Failure to do so can cause severe personal injury ordeath.Wiring must be N.E.C. Class 1.If rollout thermal fuse element wire supplied with boilermust be replaced, type 200 °C wire or equivalentmust be used. If other original wiring supplied withboiler must be replaced, use only type 105 °C wire orequivalent.Boiler must be electrically grounded as required byNational 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 Part 1, and

any local codes.

Figure 11 Field wiring connections — service switch and thermostat (or end switch) provided by installer

6 Field wiring

Wiring connectionsBoiler is shipped with controls completely wired, except spill switchand vent damper. See wiring diagram on page 17 for standing pilotignition boiler.

Thermostat1. Connect thermostat as shown on wiring diagram on boiler.2. Install on inside wall away from influences 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 equipmentconnected to it. If connected directly to boiler, set for 0.4 amps.For other devices, see manufacturer’s specifications. Wiringdiagram on boiler gives setting for control module and gas valve.Also see instructions with thermostat.

Junction box1. Connect 120 VAC power wiring (Figure 11). A separate electrical

circuit with a fused disconnect switch (15 amp. recommended)should be used for the boiler.


20 Part Number 670 01 1004 00

Follow the “Service and maintenance” procedures given throughout this manual and in component literature shipped withthe boiler. See “Read this first!” on page 2. Failure to perform the service and maintenance could result in damage to theboiler or system. Failure to follow the directions in this manual and component literature could result in severe personalinjury, death or substantial property damage.

Table 9 Service and maintenance schedules (service technician and owner)

11 Service and maintenance

Service technician(see following pages for instructions)

Owner maintenance(see User’s Information Manual for instructions)

AN

NN

UA

L S

TA

RT-U

P

❏ Inspect:

• Reported problems

• Boiler area

• Air openings

• Flue gas vent system

• Pilot and main burner flames

• Piping

• Boiler heating surfaces

• Burners and base

❏ Service:

• Gauge glass

❏ Start-up:

• Perform start-up per manual

❏ Check/test:

• Gas piping

• Boiler waterline

• Limit controls and cutoffs

• Boiler relief valve

❏ Review:

• Review with owner

❏ Daily • Check boiler area

• Check boiler pressure gauge

• Check air openings

❏ Monthly • Check boiler and system piping

• Check venting system

• Check/operate boiler relief valve

• Check pilot and main burner flames

❏ Periodically • Test low water cutoff

❏ End of season • Shut down procedure


14 Part Number 670 01 1004 00

Check for gas leaksBefore starting the boiler, and during initialoperation, smell near the floor and around the boilerfor gas odorant or any unusual odor. Do notproceed with start-up if there is any indication of agas leak. Repair any leak at once.Propane boilers only — Your propane supplier mixesan odorant with the propane to make its presencedetectable. In some instances, the odorant can fadeand the gas may no longer have an odor.

• Propane gas can accumulate at floor level. Smell nearthe floor for the gas odorant or any unusual odor. If yoususpect a leak, do not attempt to light the pilot.

• Use caution when attempting to light the propane pilot.This should be done by a qualified service 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 themarket intended for this purpose. Your supplier may beable to suggest an appropriate device.

7 Start-up

Preparation

Determine if water treatment is neededDo not use petroleum-based cleaning or sealingcompounds in boiler system. Severe damage toboiler will occur, resulting in substantial propertydamage.Eliminate all system leaks. Continual fresh makeupwater will reduce boiler life. Minerals can build upin sections, reducing heat transfer, overheatingcast iron, and causing section failure.

Consult local water treatment companies for unusually hardwater 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 water1. Do not fill (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 boilerClean all newly installed steam boilers to remove oiland grease. Failure to properly clean can result inviolent fluctuations of water level, water passing intosteam mains or high maintenance costs on strainers,traps and vents.Do not use petroleum-based cleaning or sealingcompounds in boiler system. Severe damage to boilerwill occur, resulting in substantial property damage.

1. Provide 1½" piping from skim tapping to floor drain.2. Adjust waterline to midpoint of skim tapping. See Figure 3,

page 7.3. Follow “Lighting Instructions” found on boiler or on pages 18

and 19 of this manual, to fire boiler to maintain temperature belowsteaming rate.

4. Feed in water to maintain water level. Cycle burners to preventrise in steam pressure.

5. Continue skimming until discharge is clear. May take severalhours.

6. Drain boiler. While boiler is warm, but not hot, flush all interiorsurfaces 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. Stopburners.

9. Check traps and air vents for proper operation.10. Process may need to be repeated after several weeks of

operation.

Inspect base insulationCheck to make sure insulation is secure against all four sides ofthe base. If insulation is damaged or displaced, do not operate boiler.Replace or reposition insulation.

Failure to replace damaged insulation or repositioninsulation can result in a fire hazard, causing severepersonal injury, death or substantial property damage.The boiler contains ceramic fiber and fiberglassmaterials. Use care when handling these materialsper instructions on page 32 of this manual. Failure tocomply could result in severe personal injury.

DO NOT proceed with boiler operation unless boilerand system have been filled with water and allinstructions and procedures of previous manualsections have been completed. Failure to do so couldresult in severe personal injury, death or substantialproperty damage. Before starting the boiler . . .

• See pages 18 and 19, for “Lighting Instructions”.• Verify the boiler and system water level is correct

(no more than ½ of gauge glass or less than ¼" abovebottom of gauge glass).

• Verify the “Preparation” procedures, on this page,have been completed.

Operate boiler


19Part Number 670 01 1004 00

10 Lighting Instructions — GSA-30 through GSA-50

Robertshaw 7200 gas valve

FOR YOUR SAFETY READ BEFORE LIGHTING

If you do not follow these instructions exactly, a fire or explosion may result causingproperty damage, personal injury or loss of life.

1. Set the thermostat to lowest setting.2. Turn off all electric power to the appliance if service is to be

performed.

3. Remove front panel.4. Depress and move selector arm left to OFF.5. Replace front panel.

LIGHTING INSTRUCTIONS

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.• Do not touch any electric switch; do not use any phone in

your building.

• Immediately call your gas supplier from a neighbor’sphone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the firedepartment.

A. This appliance has a pilot, which must belighted by hand. When lighting the pilot, followthese instructions exactly.

B. Before LIGHTING, smell all around theappliance area for gas. Be sure to smell nextto the floor because some gas is heavier thanair and will settle on the floor. See below.

C. Use only your hand to push down the reset button or turn the gas controlknob. Never use tools. If the knob or reset button will not operate by hand,don't try to repair it, call a qualified service technician. Force or attemptedrepair may result in a fire or explosion.

D. Do not use this appliance if any part has been under water. Immediately calla qualified service technician to inspect the appliance and to replace anypart of the control system and any gas control, which has been under water.

1. Stop! Read the safety information above on this label.2. Set the thermostat to lowest setting.3. When equipped with Effikal vent damper Model RVGP, place

service switch in Hold Damper Open position.4. Turn off all electrical power to the appliance.5. When equipped with Johnson Controls vent damper Model

M35, manually rotate damper blade in direction of arrow toOpen position indicated on damper assembly.

6. Depress and move selector arm left to OFF.7. When equipped with vent damper, verify damper blade is in

full open position.

8. Wait five (5) minutes to clear out any gas. Then smell forgas, including near the floor. If you smell gas, STOP! Follow"B" in the safety information above. If you don't smell gas,go to the next step.

9. Remove access panel located above burners.10. Find pilot — follow metal tube from gas control.

The pilot is between two burners behind theaccess panel.

11. Move selector arm on gas control right to SET position.

12. Hold selector arm in SET position and immediately light thepilot with a match. Continue to hold selector arm to SET forabout one-half (1/2) minute after the pilot is lit.

13. Release selector arm. If pilot does not remain lit, repeat steps6 through 13.

• If the pilot will not stay lit after several tries, move selectorarm left to OFF and call your service technician or gassupplier.

14. Replace access panel.15. Turn selector arm left to ON.16. Turn on all electric power to the appliance.17. When equipped with Effikal vent damper, place service

switch in Automatic Operation position.18. Set thermostat to desired setting.19. Replace front panel.

TO TURN OFF GAS TO THE APPLIANCE


15Part Number 670 01 1004 00

Check burner flame — Pilot burnerProper pilot flame (see Figure 12):1. Blue flame.2. Inner cone engulfing thermocouple.3. Thermocouple glowing cherry red.Improper pilot flame:1. Overfired — Large flame lifting or blowing past thermocouple.

Verify operation

2. Underfired — Small flame. Inner cone not engulfingthermocouple.

3. Lack of primary air — Yellow flame tip.4. Incorrectly heated thermocouple.

Check burner flames — Main burnerProper main burner flame (see Figure 13):1. Yellow-orange streaks may appear (caused by dust).Improper main burner flame:1. Overfired — Large flames.2. Underfired — Small flames.3. Lack of primary air — Yellow tipping on flames (sooting will

occur).

Figure 13Typical mainburner flame

Figure 12Typical pilotburner flame

Operate boiler continued

Start the boiler1. 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 “Lighting Instructions” on page 18 or 19, depending

on gas valve installed in boiler. Use only the “Lighting Instruction”which applies to this gas valve. (The “Lighting Instruction” labelon the boiler provides the same information.)

4. If boiler fails to start, see “If boiler doesn’t start . . . Check for:”on this page.

Check system and boilerEliminate all system leaks. Continual fresh makeupwater will reduce boiler life. Minerals can build up insections, reducing heat transfer, overheating cast iron,and causing section failure.If you discover evidence of any gas leak, shut downthe boiler at once. Find the leak source with bubbletest and repair immediately. Do not start boiler againuntil corrected. Failure to comply could result insevere personal injury, death or substantial propertydamage.Do not use petroleum-based cleaning or sealingcompounds in boiler system. Severe damage to boilerwill occur, resulting in substantial property damage.

1. Check system piping for leaks. If found, shut down boiler andrepair immediately.

2. Inspect vent system thoroughly for signs of deterioration fromcorrosion, physical damage or sagging. Verify that masonrychimney liners are in good condition, with no obstructions, andthere are no openings into the chimney.

3. Check around the boiler for gas odor following the procedure of“Check for gas leaks”, page 14.

4. Verify operation using procedures below. Perform “Checkoutprocedure”, page 16, and fill in the “Installation and servicecertificate”.

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

“Troubleshooting”, page 24.

7 Start-up continued

Check vent damper operation1. 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 burnerslight. If vent damper does not fully open, flue productssuch as carbon monoxide will escape into house,causing severe personal injury or death.

3. Lower thermostat setting — Main burner flames will go out, thenvent damper will close.

4. Repeat Steps 2 through 4 several times to verify operation.5. Return thermostat to normal setting.6. Set thermostat heat anticipator setting indicated on wiring

diagram.

Check venting system operation1. With boiler firing, hold a candle or match below lower edge of

draft diverter “skirt.” If flame does not blow out, but burnsundisturbed, the vent system is working properly. If flame blowsout or flickers severely, the vent system must be checked forobstructions or other causes of improper venting.


18 Part Number 670 01 1004 00

10 Lighting Instructions — GSA standing pilot boilers

Honeywell VR8200/VR8300 gas valve







your building.






6. Turn gas control knob clockwise to OFF.7. When equipped with vent damper, verify damper blade is in

full open position.




11. Turn gas control knob counterclockwise toPILOT.

12. Push in red reset button and hold. Immediately light the pilotwith a match. Continue to hold reset button in for about one(1) minute after the pilot is lit.

13. Release reset button. Pilot should remain lit. If pilot goes out,repeat steps 6 through 13.

• If reset button stays depressed after release, stop andimmediately call your service technician or gas supplier.

• If the pilot will not stay lit after several tries, turn the gas controlknob clockwise to OFF and call your service technicianor gas supplier.

14. Replace access panel.15. Turn gas control knob counterclockwise to ON.16. Turn on all electric power to the appliance.17. When equipped with Effikal vent damper, place service switch

in Automatic Operation position.18. Set thermostat to desired setting.19. Replace front panel.

1. Set the thermostat to lowest setting.2. Turn off all electric power to the appliance if service is to

be performed.

3. Remove front panel.4. Turn gas control knob clockwise to OFF.5. Replace front panel.






16 Part Number 670 01 1004 00

Boiler model _______________________________________________________________ Series ____________

CP number _______________________________________ Date installed _________________________________

Measured Btuh input ____________

Installer _______________________ ______________________________ ____________________________ (company) (address) (phone)

_____________________________________

(installer’s signature)

8 Checkout procedure

❏ Boiler filled with water?❏ Boilers properly skimmed?❏ Air purged from gas piping? Piping checked for leaks?❏ Correctly-sized manifold orifices installed? See Table 3, page 6,

to check size and fuel type.Correctly sized manifold orifices must be used. Failureto do so will cause severe personal injury, death orsubstantial property damage.

❏ Button on spill switch pushed in?❏ Followed “Lighting Instructions” on boiler or in Manual Section

10, pages 18 and 19, for proper start-up?❏ Proper burner flame observed? See “Verify operation”, page 15.❏ Test limit control — While burners are operating, move indicator

on limit control below actual boiler pressure. Burners should gooff. Raise setting on limit control above boiler pressure andburners should reignite.

❏ Test low water cutoff — Check probe-type low water cutoff forproper 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. Refill 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 field-installed controls — If boiler has an additionalhigh limit, low water cutoff or other controls, test for operationas outlined by manufacturer. Burners should be operating andshould go off when controls are tested. When controls arerestored, burners should reignite.

❏ Test ignition system safety device — Turn gas cock knob toPILOT position and extinguish pilot flame. Pilot gas flow shouldstop in less than 3 minutes. Put system back into operation(see Section 7, pages 14-15).

❏ Set limit control(s) to system pressure requirements. Adjustbalancing valves and controls to provide design pressure tosystem.

❏ Verify thermostat heat anticipator (if available) set properly? See“Thermostat”, page 13.

❏ Cycle boiler with thermostat — Raise to highest setting andverify boiler goes through normal start-up cycle. Lower to lowestsetting 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 1000number of seconds from step c

= Btuh

e. Btuh calculated should approximate input rating on boilerrating label.

❏ Check manifold gas pressure by connecting manometer todownstream test tapping on main gas valve. Manifold pressurefor natural gas should be 3.5" w.c. and for propane gas shouldbe 10" w.c.

❏ Observe several operating cycles for proper operation.❏ Set room thermostat to desired room temperature.❏ Fill in “Installation and service certificate” below?❏ Review all instructions shipped with this boiler with owner or

maintenance person. Return instructions to envelope and giveto owner or place in pocket inside front panel in boiler.

� Installation instructions have been followed.

� Checkout sequence has been performed.

� Above information is certified to be correct.

� Information received and left with owner/maintenance person.

Installation and service certificate


17Part Number 670 01 1004 00

Figu

re 1

4W

irin

g d

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am —

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.


16 Part Number 670 01 1004 00

Boiler model _______________________________________________________________ Series ____________

CP number _______________________________________ Date installed _________________________________

Measured Btuh input ____________

Installer _______________________ ______________________________ ____________________________ (company) (address) (phone)

_____________________________________

(installer’s signature)

8 Checkout procedure

❏ Boiler filled with water?❏ Boilers properly skimmed?❏ Air purged from gas piping? Piping checked for leaks?❏ Correctly-sized manifold orifices installed? See Table 3, page 6,

to check size and fuel type.Correctly sized manifold orifices must be used. Failureto do so will cause severe personal injury, death orsubstantial property damage.

❏ Button on spill switch pushed in?❏ Followed “Lighting Instructions” on boiler or in Manual Section

10, pages 18 and 19, for proper start-up?❏ Proper burner flame observed? See “Verify operation”, page 15.❏ Test limit control — While burners are operating, move indicator

on limit control below actual boiler pressure. Burners should gooff. Raise setting on limit control above boiler pressure andburners should reignite.

❏ Test low water cutoff — Check probe-type low water cutoff forproper 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. Refill 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 field-installed controls — If boiler has an additionalhigh limit, low water cutoff or other controls, test for operationas outlined by manufacturer. Burners should be operating andshould go off when controls are tested. When controls arerestored, burners should reignite.

❏ Test ignition system safety device — Turn gas cock knob toPILOT position and extinguish pilot flame. Pilot gas flow shouldstop in less than 3 minutes. Put system back into operation(see Section 7, pages 14-15).

❏ Set limit control(s) to system pressure requirements. Adjustbalancing valves and controls to provide design pressure tosystem.

❏ Verify thermostat heat anticipator (if available) set properly? See“Thermostat”, page 13.

❏ Cycle boiler with thermostat — Raise to highest setting andverify boiler goes through normal start-up cycle. Lower to lowestsetting 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 1000number of seconds from step c

= Btuh

e. Btuh calculated should approximate input rating on boilerrating label.

❏ Check manifold gas pressure by connecting manometer todownstream test tapping on main gas valve. Manifold pressurefor natural gas should be 3.5" w.c. and for propane gas shouldbe 10" w.c.

❏ Observe several operating cycles for proper operation.❏ Set room thermostat to desired room temperature.❏ Fill in “Installation and service certificate” below?❏ Review all instructions shipped with this boiler with owner or

maintenance person. Return instructions to envelope and giveto owner or place in pocket inside front panel in boiler.

� Installation instructions have been followed.

� Checkout sequence has been performed.

� Above information is certified to be correct.

� Information received and left with owner/maintenance person.

Installation and service certificate


17Part Number 670 01 1004 00

Figu

re 1

4W

irin

g d

iagr

am —

Sta

ndin

g p

ilot s

yste

m

9S

equence o

f opera

tion

Fol

low

all

proc

edur

es g

iven

in th

is m

anua

l and

“Lig

htin

g In

stru

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ns” w

hen

oper

atin

g th

e bo

iler.

Failu

re to

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so c

ould

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sev

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inju

ry,

deat

h or

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age.

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fter

pilo

t is

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ually

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valv

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as a

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aint

ains

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t as

long

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the

ther

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nth

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l fo

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n th

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osta

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iler

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ent

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per

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. Bur

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: Whe

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, the

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.


15Part Number 670 01 1004 00

Check burner flame — Pilot burnerProper pilot flame (see Figure 12):1. Blue flame.2. Inner cone engulfing thermocouple.3. Thermocouple glowing cherry red.Improper pilot flame:1. Overfired — Large flame lifting or blowing past thermocouple.

Verify operation

2. Underfired — Small flame. Inner cone not engulfingthermocouple.

3. Lack of primary air — Yellow flame tip.4. Incorrectly heated thermocouple.

Check burner flames — Main burnerProper main burner flame (see Figure 13):1. Yellow-orange streaks may appear (caused by dust).Improper main burner flame:1. Overfired — Large flames.2. Underfired — Small flames.3. Lack of primary air — Yellow tipping on flames (sooting will

occur).

Figure 13Typical mainburner flame

Figure 12Typical pilotburner flame

Operate boiler continued

Start the boiler1. 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 “Lighting Instructions” on page 18 or 19, depending

on gas valve installed in boiler. Use only the “Lighting Instruction”which applies to this gas valve. (The “Lighting Instruction” labelon the boiler provides the same information.)

4. If boiler fails to start, see “If boiler doesn’t start . . . Check for:”on this page.

Check system and boilerEliminate all system leaks. Continual fresh makeupwater will reduce boiler life. Minerals can build up insections, reducing heat transfer, overheating cast iron,and causing section failure.If you discover evidence of any gas leak, shut downthe boiler at once. Find the leak source with bubbletest and repair immediately. Do not start boiler againuntil corrected. Failure to comply could result insevere personal injury, death or substantial propertydamage.Do not use petroleum-based cleaning or sealingcompounds in boiler system. Severe damage to boilerwill occur, resulting in substantial property damage.

1. Check system piping for leaks. If found, shut down boiler andrepair immediately.

2. Inspect vent system thoroughly for signs of deterioration fromcorrosion, physical damage or sagging. Verify that masonrychimney liners are in good condition, with no obstructions, andthere are no openings into the chimney.

3. Check around the boiler for gas odor following the procedure of“Check for gas leaks”, page 14.

4. Verify operation using procedures below. Perform “Checkoutprocedure”, page 16, and fill in the “Installation and servicecertificate”.

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

“Troubleshooting”, page 24.

7 Start-up continued

Check vent damper operation1. 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 burnerslight. If vent damper does not fully open, flue productssuch as carbon monoxide will escape into house,causing severe personal injury or death.

3. Lower thermostat setting — Main burner flames will go out, thenvent damper will close.

4. Repeat Steps 2 through 4 several times to verify operation.5. Return thermostat to normal setting.6. Set thermostat heat anticipator setting indicated on wiring

diagram.

Check venting system operation1. With boiler firing, hold a candle or match below lower edge of

draft diverter “skirt.” If flame does not blow out, but burnsundisturbed, the vent system is working properly. If flame blowsout or flickers severely, the vent system must be checked forobstructions or other causes of improper venting.


18 Part Number 670 01 1004 00

10 Lighting Instructions — GSA standing pilot boilers

Honeywell VR8200/VR8300 gas valve







your building.






6. Turn gas control knob clockwise to OFF.7. When equipped with vent damper, verify damper blade is in

full open position.




11. Turn gas control knob counterclockwise toPILOT.

12. Push in red reset button and hold. Immediately light the pilotwith a match. Continue to hold reset button in for about one(1) minute after the pilot is lit.

13. Release reset button. Pilot should remain lit. If pilot goes out,repeat steps 6 through 13.

• If reset button stays depressed after release, stop andimmediately call your service technician or gas supplier.

• If the pilot will not stay lit after several tries, turn the gas controlknob clockwise to OFF and call your service technicianor gas supplier.

14. Replace access panel.15. Turn gas control knob counterclockwise to ON.16. Turn on all electric power to the appliance.17. When equipped with Effikal vent damper, place service switch

in Automatic Operation position.18. Set thermostat to desired setting.19. Replace front panel.

1. Set the thermostat to lowest setting.2. Turn off all electric power to the appliance if service is to

be performed.

3. Remove front panel.4. Turn gas control knob clockwise to OFF.5. Replace front panel.






14 Part Number 670 01 1004 00

Check for gas leaksBefore starting the boiler, and during initialoperation, smell near the floor and around the boilerfor gas odorant or any unusual odor. Do notproceed with start-up if there is any indication of agas leak. Repair any leak at once.Propane boilers only — Your propane supplier mixesan odorant with the propane to make its presencedetectable. In some instances, the odorant can fadeand the gas may no longer have an odor.

• Propane gas can accumulate at floor level. Smell nearthe floor for the gas odorant or any unusual odor. If yoususpect a leak, do not attempt to light the pilot.

• Use caution when attempting to light the propane pilot.This should be done by a qualified service 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 themarket intended for this purpose. Your supplier may beable to suggest an appropriate device.

7 Start-up

Preparation

Determine if water treatment is neededDo not use petroleum-based cleaning or sealingcompounds in boiler system. Severe damage toboiler will occur, resulting in substantial propertydamage.Eliminate all system leaks. Continual fresh makeupwater will reduce boiler life. Minerals can build upin sections, reducing heat transfer, overheatingcast iron, and causing section failure.

Consult local water treatment companies for unusually hardwater 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 water1. Do not fill (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 boilerClean all newly installed steam boilers to remove oiland grease. Failure to properly clean can result inviolent fluctuations of water level, water passing intosteam mains or high maintenance costs on strainers,traps and vents.Do not use petroleum-based cleaning or sealingcompounds in boiler system. Severe damage to boilerwill occur, resulting in substantial property damage.

1. Provide 1½" piping from skim tapping to floor drain.2. Adjust waterline to midpoint of skim tapping. See Figure 3,

page 7.3. Follow “Lighting Instructions” found on boiler or on pages 18

and 19 of this manual, to fire boiler to maintain temperature belowsteaming rate.

4. Feed in water to maintain water level. Cycle burners to preventrise in steam pressure.

5. Continue skimming until discharge is clear. May take severalhours.

6. Drain boiler. While boiler is warm, but not hot, flush all interiorsurfaces 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. Stopburners.

9. Check traps and air vents for proper operation.10. Process may need to be repeated after several weeks of

operation.

Inspect base insulationCheck to make sure insulation is secure against all four sides ofthe base. If insulation is damaged or displaced, do not operate boiler.Replace or reposition insulation.

Failure to replace damaged insulation or repositioninsulation can result in a fire hazard, causing severepersonal injury, death or substantial property damage.The boiler contains ceramic fiber and fiberglassmaterials. Use care when handling these materialsper instructions on page 32 of this manual. Failure tocomply could result in severe personal injury.

DO NOT proceed with boiler operation unless boilerand system have been filled with water and allinstructions and procedures of previous manualsections have been completed. Failure to do so couldresult in severe personal injury, death or substantialproperty damage. Before starting the boiler . . .

• See pages 18 and 19, for “Lighting Instructions”.• Verify the boiler and system water level is correct

(no more than ½ of gauge glass or less than ¼" abovebottom of gauge glass).

• Verify the “Preparation” procedures, on this page,have been completed.

Operate boiler


19Part Number 670 01 1004 00

10 Lighting Instructions — GSA-30 through GSA-50

Robertshaw 7200 gas valve



1. Set the thermostat to lowest setting.2. Turn off all electric power to the appliance if service is to be

performed.

3. Remove front panel.4. Depress and move selector arm left to OFF.5. Replace front panel.




your building.










6. Depress and move selector arm left to OFF.7. When equipped with vent damper, verify damper blade is in

full open position.




11. Move selector arm on gas control right to SET position.

12. Hold selector arm in SET position and immediately light thepilot with a match. Continue to hold selector arm to SET forabout one-half (1/2) minute after the pilot is lit.

13. Release selector arm. If pilot does not remain lit, repeat steps6 through 13.

• If the pilot will not stay lit after several tries, move selectorarm left to OFF and call your service technician or gassupplier.

14. Replace access panel.15. Turn selector arm left to ON.16. Turn on all electric power to the appliance.17. When equipped with Effikal vent damper, place service

switch in Automatic Operation position.18. Set thermostat to desired setting.19. Replace front panel.



13Part Number 670 01 1004 00

For your safety, turn off electrical power supply atservice entrance panel before making any electricalconnections to avoid possible electric shock hazard.Failure to do so can cause severe personal injury ordeath.Wiring must be N.E.C. Class 1.If rollout thermal fuse element wire supplied with boilermust be replaced, type 200 °C wire or equivalentmust be used. If other original wiring supplied withboiler must be replaced, use only type 105 °C wire orequivalent.Boiler must be electrically grounded as required byNational 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 Part 1, and

any local codes.

Figure 11 Field wiring connections — service switch and thermostat (or end switch) provided by installer

6 Field wiring

Wiring connectionsBoiler is shipped with controls completely wired, except spill switchand vent damper. See wiring diagram on page 17 for standing pilotignition boiler.

Thermostat1. Connect thermostat as shown on wiring diagram on boiler.2. Install on inside wall away from influences 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 equipmentconnected to it. If connected directly to boiler, set for 0.4 amps.For other devices, see manufacturer’s specifications. Wiringdiagram on boiler gives setting for control module and gas valve.Also see instructions with thermostat.

Junction box1. Connect 120 VAC power wiring (Figure 11). A separate electrical

circuit with a fused disconnect switch (15 amp. recommended)should be used for the boiler.


20 Part Number 670 01 1004 00

Follow the “Service and maintenance” procedures given throughout this manual and in component literature shipped withthe boiler. See “Read this first!” on page 2. Failure to perform the service and maintenance could result in damage to theboiler or system. Failure to follow the directions in this manual and component literature could result in severe personalinjury, death or substantial property damage.

Table 9 Service and maintenance schedules (service technician and owner)

11 Service and maintenance

Service technician(see following pages for instructions)

Owner maintenance(see User’s Information Manual for instructions)

AN

NN

UA

L S

TA

RT-U

P

❏ Inspect:

• Reported problems

• Boiler area

• Air openings

• Flue gas vent system

• Pilot and main burner flames

• Piping

• Boiler heating surfaces

• Burners and base

❏ Service:

• Gauge glass

❏ Start-up:

• Perform start-up per manual

❏ Check/test:

• Gas piping

• Boiler waterline

• Limit controls and cutoffs

• Boiler relief valve

❏ Review:

• Review with owner

❏ Daily • Check boiler area

• Check boiler pressure gauge

• Check air openings

❏ Monthly • Check boiler and system piping

• Check venting system

• Check/operate boiler relief valve

• Check pilot and main burner flames

❏ Periodically • Test low water cutoff

❏ End of season • Shut down procedure


12 Part Number 670 01 1004 00

Table 8 Pipe capacity for 0.60 specific gravity natural gas

5 Install gas piping

Natural Gas:1. See Table 8 for pipe length and diameter. Base on rated

boiler input, found on page 31 (divide by 1,000 to obtaincubic feet per hour). Table 8 is only for gas with specific gravity0.60, with a pressure drop through the gas piping of 0.30"w.c. For additional gas pipe sizing information, see ANSIZ223.1 (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 ifinlet 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.

1. Remove jacket front panel and see Figure 10 to pipe gas toboiler.a. Install drip leg at inlet of gas connection to boiler. Where

local utility requires drip leg to be extended to the floor, useappropriate 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 utilityrequirements.

d. In Canada — When using manual main shutoff valve, it mustbe 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 flame —Use bubble test. Failure to use bubble test or checkfor gas leaks can cause severe personal injury, deathor substantial property damage.

5. Use pipe dope compatible with propane gases. Apply sparinglyonly to male threads of pipe joints so that pipe dope does notblock gas flow.

Failure to apply pipe dope as described in this manualcan result in severe personal injury, death orsubstantial property damage.

Connecting gas supply piping to boiler

Gas pipe

length(feet)

Capacity of pipe for pipe size of:(Capacity in standard 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

Figure 10 Gas supply piping


21Part Number 670 01 1004 00

The boiler should be inspected and started annually,at the beginning of the heating season, only by aqualified service technician. In addition, themaintenance and care of the boiler designated in Table9, page 20 and explained on the following pages mustbe performed to assure maximum boiler efficiencyand reliability. Failure to service and maintain the boilerand system could result in equipment failure.Electrical shock hazard — Turn off power to the boilerbefore any service operation on the boiler except asnoted otherwise in this manual. Failure to turn offelectrical power could result in electrical shock,causing severe personal injury or death.The boiler contains ceramic fiber and fiberglassmaterials. Use care when handling these materialsper instructions on page 32 of this manual. Failure tocomply could result in severe personal injury.

❏❏❏❏❏ Inspect . . . . . . . . . .Reported problemsInspect any problems reported by owner and correct beforeproceeding.

Boiler area1. Verify that boiler area is free of any combustible materials,

gasoline and other flammable vapors and liquids.2. Verify that boiler area is free of any of the contaminants listed in

Table 2 on page 5 of this manual. If any of these are present inthe boiler intake air vicinity, they must be removed. If they cannotbe removed, install combustion air piping to the boiler inaccordance with national, provincial or local codes.

Air openings1. Verify that combustion and ventilation air openings to the boiler

room and/or building are open and unobstructed. Checkoperation and wiring of automatic combustion air dampers, ifused.

2. Verify that boiler vent discharge and air intake are clean andfree of obstructions.

Flue gas vent system1. Visually inspect entire flue gas venting system for blockage,

deterioration or leakage. Repair any joints that show signs ofleakage in accordance with vent manufacturer’s instructions.

2. Verify that masonry chimneys are lined, lining is in goodcondition, and there are not openings into the chimney.

Failure to inspect for the above conditions and havethem repaired can result in severe personal injury ordeath.

Pilot and main burner flames1. Visually inspect pilot burner and main burner flames as directed

under Section 7, page 15 of this manual.

Piping1. Check the boiler interior piping and all system piping for signs

of leaks.2. Repair any leaks before proceeding.

Do not use petroleum-based cleaning or sealingcompounds in boiler system. Severe damage to boilerwill occur, resulting in substantial property damage.

Eliminate all system or boiler leaks. Continual freshmakeup water will reduce boiler life. Minerals canbuild up in sections, reducing heat transfer,overheating cast iron, and causing section failure.Leaking water may also cause severe propertydamage.

Boiler heating surfaces1. Disconnect the vent pipe at the boiler draft diverter and remove

draft diverter after turning off power to the boiler.2. Use a bright light to inspect the boiler flue collector and heating

surfaces.3. If the vent pipe or boiler interior surfaces show evidence of

soot, follow “Cleaning boiler heating surfaces”, page 23. Removethe flue collector and clean the boiler if necessary after closerinspection of boiler heating surfaces.

4. If there is evidence of rusty scale deposits on boiler surfaces,check the water piping and control system to make sure theboiler return water temperature is properly maintained (per thismanual).

5. Reconnect vent and draft diverter. Replace all boiler componentsbefore returning to service.

6. Check inside and around boiler for evidence of any leaks fromthe boiler. If found, locate source of leaks and repair.

Burners and base1. After turning off power to the boiler, remove the jacket door and

base access panel (Figure 16, item 4, page 26).2. Inspect burners and all other components in the boiler base.3. If burners must be cleaned, raise rear of each burner to release

from support slot, slide forward and remove. Then brush andvacuum the burners thoroughly, making sure all ports are freeof debris. Carefully replace all burners, making sure burner withpilot bracket is replaced in its original position and all burnersare upright (ports up).

4. Inspect the base insulation.The boiler contains ceramic fiber and fiberglassmaterials. Use care when handling these materialsper instructions on page 32 of this manual. Failure tocomply could result in severe personal injury.

a. Verify that the insulation is intact and secure against all foursides of the base.

If insulation is damaged or displaced, do not operatethe boiler. Replace or reposition insulation asnecessary. Failure to replace damaged insulation canresult in a fire hazard, causing severe personal injury,death or substantial property damage.

❏❏❏❏❏ Inspect . . . . . . . . . .



11Part Number 670 01 1004 00

Figure 8 Controls

4 Install controls

Figure 9 Float-type low water cutoff(when provided by others)

Float-type low water cutoff (when provided by others)1. Install low water cutoff as shown in Figure 9, 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 floor close to floor drain toeliminate potential of severe burns. Do not plug, valveor place any obstruction in blowdown line.

3. Water feeders are not recommended for primary control. A lowwater cutoff with pump controller is recommended with acondensate receiver and feed pump.

ControlsFailure to properly install, pipe and wire boiler controlsmay result in severe damage to the boiler, buildingand personnel.

1. Controls are mounted and wired as shown in Figure 8. for actualtapping 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 on page 17.


22 Part Number 670 01 1004 00


Gas piping1. Sniff near floor and around boiler area for any indication of a

gas leak.2. Test gas piping using bubble test, per page 12 of this manual, if

there is any indication of a leak.

Boiler waterlineNormal waterline is halfway up gauge glass.

Limit controls1. Inspect and test the boiler limit control. Verify operation by turning

control set point below boiler pressure. Boiler should cycle off.Return dial to original setting.

Gauge glassNormal waterline is halfway up gauge glass. Clean when needed.1. Close lower gauge cock.2. Open pet cock.3. Open lower gauge cock and allow a small amount of water to

flush out through open pet cock.4. Close pet cock.5. Open lower gauge cock.

Boiler pressure must be low to eliminate potential ofsevere burns.If gauge glass breaks, close bot gauge cocks.Replace gauge glass. Do not replace with thin glasstubing. Failure to comply could cause severe personalinjury, death or substantial property damage.

❏❏❏❏❏ Service. . . . . . . . . . ❏❏❏❏❏ Check/test. . . . . . . . . .

❏❏❏❏❏ Start-up. . . . . . . . . .

1. Perform “Start-up” procedures, Section 7, pages 14-15, including“Verify operation” of burners and vent damper on page 15.

2. Check gas piping, per pages 12 and 14, verifying no indicationsof leakage and all piping and connections are in good condition.

3. Read the “Lighting Instructions” (page 18 or 19, whicheverapplies based on boiler gas valve).

4. Start the boiler following the “Lighting Instructions”, page 18or 19.

❏❏❏❏❏ Check/test. . . . . . . . . .

Low water cutoffs

Probe-type low water cutoff (see below)Clean probe-type low water cutoff for proper operation.1. Turn off power to boiler and wait 5 minutes.2. Drain water to bottom of gauge glass.3. Turn on power.4. Set thermostat to call for heat. Red neon lamp on lower water

cutoff should light.5. Wait 5 minutes. Boiler should not fire.6. Refill boiler to correct waterline. Red lamp should go off.7. Wait 5 minutes. Boiler should fire.8. Return thermostat to normal setting.

Float-type low water cutoff (when provided by others— see below)Clean float-type low water cutoff (when provided by others) to clearfloat chamber of sediment.1. Open blowdown valve at bottom control.2. Drain water into a bucket.

Scald potential. Boiler pressure must be low to avoidthe potential of severe burns from steam.

3. Check float-type low water cutoff for proper operation:a. Turn operating control to call for heat.b. Before water gets hot, drain to bottom of gauge glass. Boiler

should shut off after water level lowers a few inches.c. Refill boiler to correct waterline. Boiler should come back

on.


10 Part Number 670 01 1004 00

3 Install piping continued

Modern steam boilers are designed to steam for less time thanolder, larger boilers. When replacing an older steam boiler the systemcondensate return time may be longer than the steaming time. Thiscould cause the following problems:1. Boilers fitted with an automatic water feed could overfill.2. Units fitted 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 areservoir pipe is required to lengthen steaming time for a residentialinstallation: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 tothe 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 morethan 10 minutes, a reservoir pipe (or boiler feed system) isrecommended. See Table 6, this page, for suggested reservoir pipesize. Install as shown in Figure 7, below.For larger systems (as noted in Table 6), use a boiler feed systemwith a condensate tank and feed pump. You will have to install a lowwater cutoff/pump control on the boiler to operate the pump. UseTable 7 to size boiler feed systems. See page 7, Table 4, for tappinglocations. (The use of a combination condensate tank and float-controlled condensate return pump is not recommended.)For most residential installations a reservoir pipe may be all that isnecessary to ensure proper operation.

Condensate return

Figure 7 Recommended piping for parallel-flowsystems with optional reservoir pipe

During operation, this valve may discharge largeamounts of steam and/or hot water. Therefore, toreduce the potential for bodily injury and propertydamage, a discharge line MUST be installed that:

• Is connected from the outlet to a safe point ofdischarge with no intervening valve.

• Allows complete drainage of both the valve and thedischarge line.

• Is independently supported and securely anchoredso as to avoid applied stress as possible.

• Terminates freely to atmosphere where anydischarge will be clearly visible and is at no risk offreezing.

• Is, over its entire length, of a pipe size equal to orgreater than that of the valve outlet.Use only schedule 40 metal pipe for discharge. (Donot use schedule 80, extra strong or double strongpipe or connections.) DO NOT CAP, PLUG OROTHERWISE OBSTRUCT DISCHARGE PIPEOUTLET! If discharge is piped upward, a condensatedrain must be provided in the elbow below the verticalpipe to prevent condensate from returning into thevalve. Failure to comply with these instructions willcause a dangerous spray of hot water and steamthat would cause severe personal injury or death.

Relief valve continued

Table 7 Boiler feed system sizing

Table 6 Reservoir pipe sizingBoilermodelnumber

Boilergrossoutput

Time from initial steaming to average condensatereturn (boiler steaming capacity based on 970 Btu per

pound of steam)15 minutes 20 minutes 30 minutes

MBH gallonspipe

length(feet)

gallonspipe

length(feet)

gallonspipe

length(feet)

GSA075 75 1 1 1½ 1½Use boiler feed

systemGSA100 100 1 1 2 2GSA125 125 1¼ 1¼ 2½ 2¼GSA150 150 1½ 1½ 3 2½GSA175 175 1¾ 1¾

Use boiler feed systemGSA200 200 2 2

GSA250 250 2½ 2¼Designed full capacity steaming time of modern boilers is 10 minutes.

Boilermodelnumber

I=B=Rgrossoutput(poundssteam

per hour)

Conden-sate

(gallonsper hour)

Minimum condensate receivercapacity gallons for boiler

steaming times (minutes) of:(note 1)

Suggestedfeed pumpcapacity(GPM @15 PSI)(note 2)

15 min. 30 min. 45 min. 60 min.

GSA075 63 8 2 4 6 8 0.2

GSA100 81 10 3 6 9 12 0.3

GSA125 102 12 4 7 11 14 0.4

GSA150 122 15 5 9 14 18 0.5

GSA175 142 17 5 10 15 20 0.6

GSA200 163 20 6 12 18 24 0.7

GSA250 203 24 7 14 22 29 0.8

Notes1. Maximum time to when condensate returns to boiler.2. If pump capacity exceeds capacity shown, pump can be throttled with globe or

ball valve.


23Part Number 670 01 1004 00

❏❏❏❏❏ Check/test. . . . . . . . . .Boiler relief valve1. After following the warning directions below, if the relief valve

weeps or will not seat properly, replace the relief valve.Before testing, make certain discharge pipe is properlyconnected to valve outlet and arranged to containand safely dispose of boiler discharge. Wear glovesto protect your hands from hot surfaces. Verify thatdischarge piping is installed in accordance with thismanual and the instructions on the relief valve tag.Failure to comply will expose operator and others tosevere personal injury or death.Safety relief valves should be reinspected AT LEASTONCE EVERY THREE YEARS, by a licensedplumbing contractor or authorized inspection agency,to ensure that the product has not been affected bycorrosive water conditions and to ensure that thevalve and discharge line have not been altered ortampered with illegally. Certain naturally occurringconditions may corrode the valve or its componentsover time, rendering the valve inoperative. Suchconditions are not detectable unless the valve andits components are physically removed andinspected. This inspection must only be conductedby a plumbing contractor or authorized inspectionagency — not by the owner. Failure to reinspect theboiler relief valve as directed could result in unsafepressure buildup, which can result in severe personalinjury, death or substantial property damage.Check the setting of the boiler limit control. The controlshould never be set with a pressure above 10 psig.Operating at a higher pressure can cause damageto the boiler relief valve.The boiler relief valve must be tested at least monthlyduring the heating season to verify the valve anddischarge piping flow freely. If corrosion and/ordeposits are noticed within the valve body, testingmust be performed more often. A “try lever test” mustalso be performed at the end of any non-serviceperiod. Follow the instructions below for a “try levertest”:

• With the system at operating pressure, lift and holdthe test lever fully open for at least 5 seconds to flushthe valve seat free of sediment and debris. Thenrelease lever and permit the valve to snap shut.

❏❏❏❏❏ Review with owner1. Review the User’s Information Manual with the owner.2. Emphasize the need to perform the maintenance schedule

specified in the User’s Information Manual (and in this manualas well).

3. Remind the owner of the need to call in a licensed contractorshould the boiler or system exhibit any unusual behavior.

4. Remind the owner to follow the proper shutdown procedureand to schedule an annual start-up at the beginning of the nextheating season.

The boiler contains ceramic fiber and fiberglassmaterials. Use care when handling these materialsper instructions on page 32 of this manual. Failure tocomply could result in severe personal injury.

1. Shut down boiler — Follow “To Turn Off Gas to Appliance”instructions on boiler and “Lighting Instructions”.

2. Disconnect breeching and remove damper and draft diverter.3. Remove upper rear jacket panel. Turn back jacket insulation to

expose collector hood.4. Remove collector hood. Clean excess boiler cement from

collector hood and cast iron sections.5. Remove burners from base of boiler. Follow “Burners and base”

on page 21, to thoroughly clean burners. Place newspaper inbase of boiler to collect soot that will fall.

6. With a wire flue brush, clean between the sections.7. Remove paper and soot. Vacuum or brush base and

surrounding area.8. Replace collector hood. Seal with boiler cement.

❏❏❏❏❏ Cleaning boiler heating surfaces



9Part Number 670 01 1004 00

General

3 Install piping

1. Pipe before installing controls. Connect return piping after jacketis attached. Connect supply piping before or after jacket isattached.

Failure to properly pipe the boiler may result inimproper operation and damage to the boiler orbuilding.

2. See Figure 5 and Table 5. Pipe exactly as shown. Satisfactoryoperation of a steam heating system depends on adequatecondensate return to boiler to maintain a steady water level.Avoid adding raw makeup water. Where condensate return isnot adequate, install low water cutoff/pump control, condensatereceiver and condensate boiler feed pump. Refer to Table 7,page 10, for sizing. See page 7, Table 4, for tapping locations.

Table 5 Recommended pipe sizing

Figure 5 Recommended piping, piping for parallel-flow systems only.

Connecting to counterflow pipingApply the recommended piping in Figures 4 through 7 only whenconnecting to a parallel-flow system. When connecting to acounterflow system, the boiler steam supply must connect into thetop of the counterflow system header, as shown in Figure 6.

Figure 6 Connection to counterflow steam piping

Relief valveInstall relief valve in tapping on top of boiler. See Table 4, page 7,for control tapping locations. See the tag attached to the relief valvefor manufacturer’s instructions.

Follow the steps below to avoid potential severepersonal injury, death or substantial property damage.

• When installing the relief valve, ensure that allconnections, including the valve inlet, are clean andfree from any foreign matter.

• Mount the relief valve only in the vertical position,directly connected to the tapping designated in themanual on top of the boiler.

• Use pipe compound sparingly, or tape, on externalthreads only.

• Do not use a pipe wrench! Use proper type and sizewrench on wrench pads only.

Boiler model number Riser (A) Header (H)see Note

Equalizer (J)

GSA075 and GSA100 2" 2" 1½"

GSA125 through GSA175 2½" 2 ½" 1½"

GSA200 and GSA250 3" 3" 1½"

Note: 24" minimum from waterline to header.


24 Part Number 670 01 1004 00

12 Troubleshooting

Verify proper operation after servicing. • See ventdamper manufacturer’s instructions packed with ventdamper for additional information. Failure to complycould result in severe personal injury, death orsubstantial property damage.

Figure 15 Manually opening vent damper

Label all wires prior to disconnection when servicingcontrols. Wiring errors can cause improper anddangerous operation.Never jumper (bypass) rollout thermal fuse elementor any other device except for momentary testing asoutlined in “Chart 1”, page 25. Severe personal injury,death or substantial property damage can result.Burner base access panel must be in position duringboiler operation to prevent momentary flame rollouton ignition of main flame. Severe personal injury orsubstantial property damage will result.

Before troubleshooting:1. Have the following items:

a. Voltmeter that can check 120 VAC and 24 VAC.b. Continuity checker.c. U-tube manometer.

2. Check for 120 VAC (minimum 102 VAC to maximum 132 VAC)to boiler.

3. Make sure thermostat is calling for heat and contacts (includingappropriate zone controls) are closed. Check for 24 VACbetween thermostat wire nuts and ground.

Troubleshooting sequence:1. Before proceeding, check for:

• Loose connections, blown fuse or service switch off?• High limit switch set below boiler water temperature?• Thermostat set below room temperature?• Gas not turned on at meter or boiler?• Incoming gas pressure less than:

5" w.c. for natural gas? 11" w.c. for propane gas?2. If all of the above check correctly, check gas pressures:

a. With boiler off:• 13" w.c. maximum natural or propane gas pressure

upstream of gas valve.b. With boiler on:

• 5" w.c. minimum natural gas pressure or 11" w.c.propane gas pressure upstream of gas valve.

• 3.5" w.c. minimum natural gas pressure or 10" w.c.propane gas pressure downstream tapping on gasvalve — Can be adjusted by regulator on gas valve.

c. If gas pressure is incorrect or gas is not available to boiler,contact gas supplier to correct before proceeding further.

3. Check pilot operation — Follow “Lighting Instructions”, pages18 and 19.• If gas is available and you cannot obtain a pilot flame, try

purging the gas line and cleaning pilot and pilot gas tubing.Follow “Lighting Instructions” again. If you still cannot obtaina flame, replace pilot burner and gas tubing. If this does notallow you to obtain a pilot flame, replace gas valve.

• If you obtain a pilot flame, but pilot will not remain on, replacethermocouple. If this does not correct problem, replace gasvalve and pilot burner.

• If pilot stays on, but main gas will not come on, proceed topage 25.

In event of vent damper failure:

Effikal vent damperIf troubleshooting chart recommends replacing actuator and actuatoris not immediately available, damper blade can be fixed in an openposition to allow boiler operation. Manually turning blade can causeactuator damage. Follow these instructions only in case of no heator damper actuator malfunction.1. Move damper service switch to Hold Damper Open position.

Apply call for heat to boiler. Damper blade should then rotate toOpen position and boiler will fire.

2. If step 1 does not open damper, manually rotate damper bladeto open position using wrench or pliers on flat shaft betweendamper and actuator. Boiler will fire. Verify that damper serviceswitch is in Hold Damper Open position. See Figure 15.


Johnson Controls vent damperIf troubleshooting chart recommends replacing actuator and actuatoris not immediately available, damper blade can be fixed in an openposition to allow boiler operation. Follow these instructions only incase of no heat or damper actuator malfunction. See Figure 15.1. Turn off power to boiler.

Failure to turn off power to boiler can result in severepersonal injury, death or substantial property damage.

2. See vent damper manufacturer’s instructions for procedure tofix vent damper in open position.

3. Turn on power to boiler.4. Using wrench or pliers on flat shaft section, manually rotate

damper blade until green light turns on. Boiler will fire. SeeFigure 15.



8 Part Number 670 01 1004 00

4. Read and apply the harness plug warning label (shown above)so that it is visible after installation

5. Plug damper harness receptacle into damper harness plug.Bypassing (jumpering) vent damper will cause flueproducts such as carbon monoxide to escape intothe house. This will cause severe personal injury ordeath.After boiler has operated once, if either end of harnessis disconnected, the system safety shutdown willoccur. The boiler will not operate until harness isreconnected.Effikal damper — Damper hold open switch must bein Automatic Operation position for system to operateproperly.


Figure 4 Vent damper assemblies

Vent damperThese systems are used on gas-fired boilers withvent dampers as shipped from factory. Boiler will notoperate without vent damper installed.

Damper bladeSee vent manufacturer’s instructions to install plug (shipped withdamper) in damper hole. Install plug with 3/8" diameter hole in ventdamper hole.

Minimum clearancesProvide a minimum of 6" between the vent damper and anycombustible material. (See “Minimum clearance to combustiblematerials,” page 3, for minimum clearance from jacket top to ceilingto maintain this dimension.)

Damper installationDo not modify draft diverter or vent damper, or makeanother connection between draft diverter and ventdamper or boiler except as noted below. This will voidCSA certification and will not be covered byWilliamson-Thermoflo warranty. Any changes willcause severe personal injury, death or substantialproperty damage.

1. Install vent damper as shown in vent damper manufacturer’sinstructions. Vent damper must be installed so that it servesonly one boiler and so damper blade indicator is visible to theuser. See Figure 4.

2. Screws or rivets used to secure the vent damper to the draftdiverter must not interfere with rotation of the damper blade.

3. Install damper harness between damper actuator and knockoutin jacket top panel. Use strain relief connectors and locknuts tosecure both ends of damper harness.

Keep wiring harness clear of all hot surfaces. Wireinsulation could be damaged, causing risk of electricalshort-circuit.


25Part Number 670 01 1004 00

Is 24VAC present across transformer terminals C & Y?

Is damper harness securely plugged in at both ends?Secure connections.

Check for open thermostat, LWCO, high limit, spill switch orrollout thermal fuse element contacts or check for loosewire connections.

If LWCO, spill switch or rollout thermal fuseelement contacts are open, determine causeand correct condition. Failure to do so willcause severe personal injury, death orsubstantial property damage.

Check/repair out of round stack section. Does vent damperrotate open?

Is 24VAC present across transformer terminal C and yellowwire on vent damper connector?

Is 24VAC present across gas valve terminals?

Open thermostat contacts for 30 seconds. Vent damper willrotate to closed position. Close thermostat contacts. Ventdamper will rotate to open position. Is 24VAC presentacross gas valve terminals?

Remove damper harness fromdamper harness plug.TEMPORARILY install jumperbetween terminal 2 andterminal 5 on damper plug inboiler wiring harness. SeeTable, right. Does boiler fire?

No Yes

No Yes

Chart 1 — Standing pilot — Boiler will not fire

Check for loose wire connections or bad relay ontransformer.

No Yes

Is vent damper rotated open?

No Yes

No Yes

Replace actuator.Retest.

Check continuity of each wire in damper harness. Doescontinuity exist for each wire? See Table right.

Replace damperwiring harness.Retest.

Replace gas valve.Retest.

Is main flame on now?

No Yes

Retest

No Yes

No Yes

No Yes

No Yes

Replace damperactuator. Retest.

Turn gas valve cock toON position. Retest.

Replace gas valve.Retest

Is gas valve cock turned to ON position?

No Yes

Before proceeding, follow "Troubleshooting sequence" on page 24. If problem persists, then:

12 Troubleshooting continued


7Part Number 670 01 1004 00


Pressure test continued Draft diverter & spill switch

Draft diverter installation1. Secure draft diverter to flue collector hood with sheet metal

screws. See Figure 16, items 1 and 9, on page 26. Use boilercement to provide gas tight seal.

Failure to maintain gas-tight seal can cause flue gasspillage and carbon monoxide emissions, resultingin severe personal injury or death.Do not alter boiler draft diverter or place anyobstruction or non-approved vent damper inbreeching or vent system. CSA certification willbecome void. Flue gas spillage and carbon monoxideemissions will occur causing severe personal injuryor death.

Spill switch installation1. Fasten spill switch to draft diverter as shown in Figure 16, item

20, page 26.2. See Wiring diagram on page 17 to connect wires.

Install vent piping1. Connect from draft diverter or vent damper outlet to chimney or

vent with same size vent connector.

2. Where possible, vertical venting to the outside from the draftdiverter or vent damper outlet will offer best performance.

3. Where horizontal vent connector is used, slope upward at least¼" per lineal foot toward chimney or vent and support withhangers to prevent sagging.

4. Breeching must not be connected to any portion of a mechanicaldraft system that can operate under positive pressure.

Long horizontal vent connector, excessive numberof elbow or tees, or other obstructions that restrictthe flow of combustion gases should be avoided.Severe personal injury, death or substantial propertydamage could result.

Drain and remove fittings1. Drain boiler and repair leaks if found.

Leaks must be repaired at once. Failure to do so candamage boiler, resulting in substantial propertydamage.Do not use petroleum based cleaning or sealingcompounds in boiler system. Severe damage to boilerwill 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, below.

Table 4 Control tapping

Figure 3 Control tapping locations

Float-type low water cutoff — If field installing a float-type low water cutoff, it must be piped only to thegauge glass tappings, items H, Figure 3. The tappingsare spaced 9" on center. Use only float-type low watercutoffs with quick-connect hookups that will providea low water cutoff point no higher than 2" above thecenter of the bottom tapping. See page 11, Figure 9,for a typical installation.

Location Size DescriptionC ¾" Probe-type low 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)

3/8" Try cock tappings

L ¼"Siphon, pressure gauge, high limit control

S 1½" Skim tapping

Note: Available only on special request.


26 Part Number 670 01 1004 00

Figure 16 Section assembly, flue collector, draft diverter, vent damper and base assembly

13 Replacement parts

Itemnumber


part number1 Draft diverter GSA075


450021285WT450021286WT450021287WT450021288WT450021289WT450021290WT450021291WT

Base insulation kit: Consists of items 3 and 13. 510811660WT2 End section, left hand, 1813 311800007WT3 Back base panel insulation (in Base insulation kit)4 Back base panel GSA075 & GSA100


451800010WT451800011WT451800012WT451800013WT

5 Back base channel GSA075 & GSA100GSA125 & GSA150GSA175 & GSA200GSA250

451800020WT451800021WT451800022WT451800023WT

6 Front base panel GSA075 & GSA100GSA125 & GSA150GSA175 & GSA200GSA250

451800000WT451800001WT451800002WT451800003WT

7 Back burner support GSA075GSA100GSA125GSA150GSA175GSA200GSA250

451800085WT451800086WT451800087WT451800088WT451800089WT451800090WT451800092WT

8 Burner pan side rail 451800070WT9 Collector hood GSA075 & GSA100


450014733WT450014734WT450014735WT450014736WT

Section replacement kit (Consists of: cope sealand 1 each 3" and 6" square cut seals)

381800100WT

Itemnumber


part number10 End section, right hand, 18118 311800029WT11 Intermediate section, 1815 311800010WT12 Tie rod, 1/2" GSA075 & GSA100


560234470WT560234475WT560234480WT560234485WT

13 Front base panel insulation (in Base insulation kit)14 Base access panel GSA075 & GSA100

GSA125 & GSA150GSA175GSA200GSA250

451800040WT451800041WT451800039WT451800042WT451800043WT

15 Burner with pilot bracket 512200021WT16 Gas valve — see “Gas controls” table on page 2917 Main burner orifice 560528987WT18 Burner manifold GSA075


591125533WT591125538WT591125534WT591125539WT591125535WT591125540WT591125541WT

19 Pilot burner assembly — see “Gas controls” table on page 2920 Spill switch 510350100WT21 Rollout thermal fuse element 512050230WT22 Vent damper 5"

6"7"8"

381800466WT381800467WT381800468WT381800469WT

23 Vent damper actuator only with ventdamper above

24 Vent damper harness 591391795WT


6 Part Number 670 01 1004 00

Air openings continued

2 Prepare boiler

Placement and setup

Place boiler/crate near position1. 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.

Inspect orifices and burners1. Remove front jacket door. Remove base access panel (see

Figure 16, item 14, page 26).2. Check for correctly-sized manifold orifices. See Table 3 for sizing.

(The orifice size is stamped on the orifice spud barrel.)Correctly-sized manifold orifices must be used. Failureto do so will result in severe personal injury, death orsubstantial property damage.

3. Level and straighten burners.Burners must be properly seated in slots in burnerrest with their openings face up. Main burner orificesmust inject down center of burner. Failure to properlyseat burners will result in severe personal injury,death or substantial property damage.

4. Reinstall base access panel.Do not operate boiler without access panel securedin place. Failure to comply could cause momentaryflame rollout on ignition of main flame, resulting inpossible fire or personal injury hazard.


Exhaust fans and air moversThe appliance space must never be under a negative pressure.Always provide air openings sized not only to the dimensionsrequired for the firing rate of all appliances, but also to handle the airmovement rate of the exhaust fans or air movers using air from thebuilding or space.

Motorized air dampersIf the air openings are fitted with motorized dampers, electricallyinterlock the damper to:• Prevent the boiler from firing 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 thedamper open) in series with the thermostat input to the boiler. Theboiler will not start if this damper is closed, and will shut down shoulddamper close during operation.

Table 3 Manifold orifice sizing

Pressure test

Perform hydrostatic pressure testPressure test boiler before attaching water or gas piping or electricalsupply.

Prepare boiler for test1. Plug tappings or openings.2. Do not use gauge supplied with boiler for pressure testing. Install

gauge with appropriate range.

Fill and pressure test1. Fill boiler with water. Vent all air. Test boilers between 45-50 psi.

Do not leave boiler unattended. A cold water fill couldexpand and cause excessive pressure resulting insevere personal injury, death or substantial propertydamage.

2. Check for maintained gauge pressure for more than 10 minutes.Visually check for leaks if gauge pressure drops.

Location Natural gas

U. S.Sea level – 2,000 ft over 2,000 ft

2.45 mm (Note 1)

CanadaSea level – 2,000 ft 2,000 – 4,500

2.45 mm 2.30 mmNote 1: For U. S. elevations above 2,000 feet, contact your Williamson-

Thermoflo supplier for details.


27Part Number 670 01 1004 00

Figure 17 Jacket assembly


Item number Description International Comfort Productspart number

1 Jacket panel, left side 421800150WT

2 Jacket panel, top GSA075 & GSA100GSA125 & GSA150GSA175 & GSA200GSA250

421800152WT421800153WT421800154WT421800155WT

3 Jacket panel, right side 421800151WT

4 Jacket panel, door GSA075 & GSA100GSA125 & GSA150GSA175 & GSA200GSA250

421800167WT421800168WT421800169WT421800170WT

5 Jacket panel, interior GSA075 & GSA100GSA125 & GSA150GSA175 & GSA200GSA250

421800162WT421800163WT421800164WT421800165WT

6 Jacket panel, rear GSA075 & GSA100GSA125 & GSA150GSA175 & GSA200GSA250

421800157WT421800158WT421800159WT421800160WT

7 Bottom cross tie GSA075 & GSA100GSA125 & GSA150GSA175 & GSA200GSA250

421800172WT421800173WT421800174WT421800175WT

8 Junction box, 4 x 4 (Available at local supply house)


5Part Number 670 01 1004 00

Table 2 Corrosive contaminants and likely locations

To prevent potential of severe personal injury or death,check for products or areas listed below beforeinstalling boiler. If any of these contaminants are found:

• Remove contaminants permanently.— OR —

• Isolate boiler and provide outside combustion air. Seenational, provincial or local codes for furtherinformation.

Please review the following information on potential combustion aircontamination problems.See Table 2 for products and areas which may cause contaminatedcombustion air.

Air contamination Air openings

Products to avoid

Spray cans containing chloro/fluorocarbons

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 refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops


Combustion air and ventilation openings must comply with Section5.3, “Air for Combustion and Ventilation”, of National Fuel Gas CodeANSI Z223.1–latest edition, or applicable local building codes.Canadian installations must comply with B149.1 or B149.2Installation Codes.See table below for minimum combustion/ventilation air openingsizes. Where openings are required, provide two (2) openings —one within 12 inches of the ceiling, the other within 12 inches of thefloor, as shown in the table illustrations.

Provide adequate combustion and ventilation air toassure proper combustion and reduce the risk ofsevere personal injury, death or substantial propertydamage caused by flue gas spillage and carbonmonoxide emissions.


28 Part Number 670 01 1004 00

Figure 18 Controls and trim


Itemnumber

Description Manufacturer Manufacturer’spart number

InternationalComfort Products

part number

1 Pressure relief valve, ASME, 15 PSIG, ¾" npt(Fittings shown are factory-installed on boiler.Coupling ¾" npt, Nipple ¾" npt)

ConbracoWatts

13-501-08315

511548023WT

2 Low water cutoff, probe-type Hydrolevel 400 511114515WT

3 Limit control/gauge assembly, includes:Pressure controlGauge, steamSiphon, ¼" npt, 90° brassNipple, close ¼" nptTee, ¼" npt

HoneywellWinter’s

PA-404-AE1437

510312135WT510218045WTobtain locallyobtain locallyobtain locally

4 Gauge glass assembly, includes:Gauge glassGauge glass guard, 9 3/8"Gauge cock set, brass Conbraco

United Brass Wks21-205-03-W905 and 946

591419185WT563334580WT510218145WT

5 Drain valve, ¾" International Comfort Products 511210423WT


4 Part Number 670 01 1004 00


Failure to follow all instructions can result in flue gasspillage and carbon monoxide emissions, causingsevere personal injury or death.

When removing boiler from existing common ventsystem:At the time of removal of an existing boiler, the following steps shallbe followed with each appliance remaining connected to the commonventing system placed in operation, while the other appliancesremaining connected to the common venting system are not inoperation.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 deficiencies which could cause an unsafecondition.

c. Test vent system — Insofar as is practical, close all buildingdoors and windows and all doors between the space in whichthe appliances remaining connected to the common ventingsystem are located and other spaces of the building. Turn onclothes dryers and any appliance not connected to the commonventing system. Turn on any exhaust fans, such as range hoodsand 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 thelighting instructions. Adjust thermostat so appliance will operatecontinuously.

e. Test for spillage at draft diverter relief opening after 5 minutesof main burner operation. Use the flame of a match or candle.

f. After it has been determined that each appliance remainingconnected to the common venting system properly vents whentested as outlined above, return doors, windows, exhaust fans,fireplace dampers, and any other gas-burning appliance to theirprevious conditions of use.

Any improper operation of common venting system should becorrected so the installation conforms with the National Fuel GasCode, ANSI Z223.1–latest edition. Correct by resizing to approachthe minimum size as determined using the appropriate tables inPart 11 of that code. Canadian installations must comply with B149.1or B149.2 Installation Code.

Chimney or vent requirements1. Venting must be installed according to Part 7, “Venting of

Do not alter boiler draft diverter or place anyobstruction or non-certified vent damper in breechingor vent system. CSA certification will become void.Flue gas spillage and carbon monoxide emissionswill occur causing severe personal injury or death.

Inspect existing chimney before installing boiler.Failure to clean or replace perforated pipe or tile liningwill cause severe personal injury or death.

Vent systemEquipment”, of National Fuel Gas Code, ANSI Z223.1–latestedition and applicable building codes. Canadian installationsmust 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 pointwhere it passes through a roof of a building, and at least2 feet higher than any portion of a building within a horizontaldistance of 10 feet.

• Type B vents with listed caps may terminate as in Figure 2if no closer than 8 feet from a vertical wall or similarobstruction.

• Otherwise, Type B vents must terminate at least 2 feet abovethe roof penetration and at least 2 feet higher than any portionof a building within 10 feet.

3. A lined chimney is preferred and must be used when requiredby local, state, provincial and national codes, laws, regulationsand ordinances. Vitreous tile linings with joints that preventretention of moisture and linings made of noncorrosive materialsare best. Advice for flue connections and chimney linings canbe obtained from local gas utility. Type B double-wall metal ventpipe 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 ventdamper is vented through this type of chimney, the potentialexists for condensation to occur. Condensation can damage amasonry chimney. Williamson-Thermoflo recommends thefollowing to prevent possible damage.a. Line chimney with corrosion-resistant metal liner such as

AL29-4C® single-wall stainless steel or B-vent. Size linerper 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 toarea of vent outlet on largest appliance plus 50 percent of ventoutlet area of additional appliances.

Figure 2 Terminations with Type B vent fitted withlisted cap, provided vent is at least 8 feetfrom any vertical wall or similar obstruction

The following requirements apply when you removean existing boiler from a vent system shared withother appliances. If the new boiler will not use thecommon vent, you must test (as described below)each remaining appliance — operating by itself — toverify that the vent system operates adequately.


29Part Number 670 01 1004 00


Figure 19 Gas controls

Itemnumber

Descript ion Manufac turer Manufac turer’spart number

Internat ionalComfortProducts

part number

Standing pilot — Natural gas components

1 Gas valve, 1/2" x 1/2", GSA075 through GSA175

Gas valve, 3/4" x 3/4", GSA200 and GSA250

HoneywellRobertshawHoneywell

VR8200A21167200ER

VR8300C4050

511044360WT

511044256WT

2 Pilot assembly kit with orifice International Comfort Products 510811640WT

3 Tubing, pilot, aluminum with fittings 560742860WT

4 Tubing, thermocouple 511724254WT

5 Transformer with receptacle HoneywellWhite-Rodgers

R8285K1004S84A-85

510312166WT

notshown

Wiring harness 591391867WT


3Part Number 670 01 1004 00

Clearances

Flooring and foundationDo not install boiler on combustible flooring orcarpeting even if a concrete or aerated foundation isused. Fire can result, causing severe personal injury,death or substantial property damage.

1. Provide a solid brick or minimum 2-inch thick concretefoundation pad if any of the following is true:• floor can become flooded.• 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 concretefloor of the boiler room.

• Concrete floor is “green”.• Water is channeled under the concrete.

Residential garage installationTake the following special precautions when installing the boiler ina residential garage. If the boiler is located in a residential garage,per ANSI Z223.1, paragraph 5.1.9:• Mount the boiler a minimum of 18 inches above the floor of the

garage to assure the burner and ignition devices will be no lessthan 18 inches above the floor.

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


Figure 1 Minimum clearances - alcove installation only

Large space — (see minimum room volume, below)If installed in a four-walled room, the room volume must be no lessthan the following (Ceiling height, if over 8 feet, can only be countedas 8 feet.):

GSA075 & GSA100 147 cubic feetGSA125 & GSA150 184 cubic feetGSA175 & GSA200 221 cubic feetGSA250 257 cubic feet

The room must provide the following minimum clearances (in alldirections) to the boiler and components:

Jacket and flue collector sides & rear 6 inchesJacket front 18 inchesVent pipe (other than Type B vent) 6 inchesVent damper 6 inches

Table 1 Minimum foundation size

Service clearances1. Provide minimum clearances for cleaning and servicing the

boiler and for access to controls and components as listed inthe table below.

2. Provide at least screwdriver clearance to jacket front panelscrews for removal of front panel for inspection and minorservice. If unable to provide at least screwdriver clearance,install unions and shutoff valves in system so boiler can bemoved for servicing.

Service clearances: Minimum

Top (for cleaning flueways) 46"Front (for access to controls and components) 18"Back 6"

Left side (for cleaning and servicing) 24"Right side 6"

Minimum clearance to combustible materials

General — all installations1. Hot water pipes must be at least ½" from combustible material.2. Single-wall vent pipe must be at least 6 inches from combustible

material.3. Type B double-wall metal vent pipe — See vent manufacturer’s

recommendation for clearances to combustible material.

Small space — alcove (not closet) installationGSA boilers are not approved for closet installation— only for alcove installation, with minimumclearances as shown in Figure 1 and the table below,and the front side completely open — that is, a 3-walled room.

Clearances from combustible materials: Minimum

Top 46"Front (provide means of access) 3"

Back 6"Left side (provide means of access) 4"Right side 4"

Boilermodel

Minimumfoundation

length

Minimumfoundation

widthGSA075 – GSA100 29 5/8" 19"GSA125 – GSA150 29 5/8" 23 1/4"

GSA175 – GSA200 29 5/8" 27 1/2"GSA250 29 5/8" 31 3/4"


30 Part Number 670 01 1004 00

Figure 20 Dimensional drawing — ALL DIMENSIONS IN INCHES

14 Dimensions

Boilermodelnumber

Supplytapping

(inches NPT)

Returntapping

(inches NPT)

Gas connection& manifold size

(Note 2)(inches NPT)

“ V”Damperheight(inches)

“ D”Vent

diameter(inches)

“ W”Jacketwidth

(inches)

Approximateshippingweight

GSA075 3 2½ 1/2 6 5 17 430

GSA100 3 2½ 1/2 6 5 17 430

GSA125 3 2½ 1/2 61/2 6 21¼ 505

GSA150 3 2½ 1/2 61/2 6 21¼ 505

GSA175 3 2½ 1/2 9 7 25½ 585

GSA200 3 2½ 1/2 9 7 25½ 585

GSA250 3 2½ 3/4 91/2 8 29¾ 660

Note 2: Size gas piping from meter to boiler per local utility requirements.


2 Part Number 670 01 1004 00

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 safelighting and other performance criteria when boilerunderwent tests specified in ANSI Z21.13–latestedition.

Before locating the boiler:❏ Check for nearby connection to:

• Venting connections• Gas supply piping• Electrical power

❏ Check area around boiler. Remove any combustible materials,gasoline and other flammable liquids.

Failure to keep boiler area clear and free ofcombustible materials, gasoline and other flammableliquids and vapors can result in severe personalinjury, death or substantial property damage.

❏ Boiler must be installed so that gas control system componentsare protected from dripping or spraying water or rain duringoperation or service.

❏ If new boiler will replace existing boiler, check for and correctsystem problems, such as:1. System leaks causing oxygen corrosion or section cracks

from hard water deposits.

Codes & checklistFailure to adhere to the guidelines below canresult in severe personal injury, death orsubstantial property damage.

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 flow 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 locationexternal to the appliance, if possible.

5. Do not use this boiler if any part has been under water.Immediately call a qualified service technician to inspectthe boiler and to replace any part of the control systemand 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 willoccur, causing leakage between boiler sections, circulatorflanges, diaphragm tanks or other system components.This can result in substantial property damage.

7. DO NOT use "homemade cures" or "boiler patentmedicines". Serious damage to boiler, personnel and/orproperty may result.

8. Continual fresh makeup water will reduce boiler life. Mineralbuildup in sections reduces heat transfer, overheats castiron, and causes section failure. Addition of oxygen andother gases can cause internal corrosion. Leaks in boileror piping must be repaired at once to prevent makeupwater.

9. Do not add cold water to hot boiler. Thermal shock cancause sections to crack.

1 Prepare boiler locationRead this first!


31Part Number 670 01 1004 00

15 Ratings

Notes1. Based on standard test procedures prescribed by the United States Department of

Energy.2. Net I=B=R ratings are based on net installed radiation of sufficient quantity for the

requirements of the building and nothing need be added for normal piping and pickup.Ratings are based on a piping and pickup allowance of 1.333. An additional allowanceshould be made for unusual piping and pickup loads.

3. See information at right for model number suffixes. Letters shown are model numbersuffixes. An “N” after the model number designates natural gas.

4. Contact your International Comfort Products dealer regarding information and partsfor high altitude applications.

DOE

Boilermodel

number

0–2,000feet altitude

2,000–4,500feet altitude

(Canada)

NetI=B=R ratings

Boiler watercontent(gallons)

(to waterline)

DOESeasonalefficiency(% A.F.U.E)

Chimneyand

breechingsize

Input(Btuh)

DOE Heating Capacity(Output) (Btuh)

Input(Btuh)

Output(Btuh)

Sq. Ft.Steam

SteamBtuh

(Note 3) (Note 1) (Note 4) (Note 2) (Note 3)

GSA075 75,000 62,000 67,500 54,000 196 47,000 8.4 81.0 5"I.D. x 20'

GSA100 100,000 83,000 90,000 72,000 258 62,000 8.4 81.3 5"I.D. x 20'

GSA125 125,000 104,000 112,500 90,000 325 78,000 9.8 81.5 6"I.D. x 20'

GSA150 150,000 125,000 135,000 108,000 392 94,000 9.8 81.6 6"I.D. x 20'

GSA175 175,000 145,000 157,500 126,000 454 109,000 11.2 81.9 7"I.D. x 20'

GSA200 200,000 167,000 180,000 144,000 521 125,000 11.2 81.9 7"I.D. x 20'

GSA250 250,000 209,000 225,000 180,000 654 157,000 12.6 82.0 8"I.D. x 20'

Part Number 670 01 1004 00

GSA

This manual must only be used by a qualified heating installer/service technician. Failure to comply could result insevere 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 numberfrom the boiler jacket. You may list the CP number in the space provided on the “Installation and service certificate” found onpage 16.

Contents Page

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

2 Prepare boiler ..................................................................... 6

3 Install piping ........................................................................ 9

4 Install controls .................................................................. 11

5 Install gas piping ............................................................... 12

6 Field wiring ....................................................................... 13

7 Start-up ............................................................................ 14

8 Checkout procedure ......................................................... 16

9 Sequence of operation ...................................................... 17

10 Lighting instructions .......................................................... 18

11 Service and maintenance ................................................. 20

12 Troubleshooting ................................................................ 24

13 Replacement parts ........................................................... 26

14 Dimensions ...................................................................... 30

15 Ratings ............................................................................. 31

Boiler Manual

Gas-Fired Steam Boilers

Hazards that will or can cause minor personal injuryor property damage.

Special instructions on installation, operation ormaintenance that are important but not related topersonal injury or property damage.

INSTALLER — Read all instructions beforeinstalling. Read page 2 first. Follow all instructionsin proper order to prevent personal injury or death.

• Consider piping and installation when determiningboiler location.

• Any claims for damage or shortage in shipmentmust be filed immediately against the transportationcompany 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 tocomply could result in severe personal injury, deathor substantial property damage.

• This manual is for use only by your qualifiedheating installer/service technician.

• Please see the User’s Information Manual for yourreference.

• Have the boiler serviced by a qualified servicetechnician, at least annually.


32 Part Number 670 01 1004 00

Handling ceramic fiber and fiberglass materials

REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS

The combustion chamber lining or base insulation panels in this product contain ceramic fiber materials. Ceramicfibers can be converted to cristobalite in very high temperature applications. The International Agency for Researchon Cancer (IARC) has concluded, "Crystalline silica inhaled in the form of quartz or cristobalite from occupationalsources is carcinogenic to humans (Group 1).":


• Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements forcristobalite at the time this document was written. Other types of respirators may be needed depending onthe job site conditions. Current NIOSH recommendations can be found on the NIOSH web site at http://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators, manufacturers, and phone numbers arealso listed on this web site.


■ Apply enough water to the combustion chamber lining or base insulation to prevent airborne dust.

■ Remove combustion chamber lining or base insulation from the boiler and place it in a plastic bag for disposal.




REMOVAL OF FIBERGLASS WOOL — OR —

INSTALLATION OF FIBERGLASS WOOL, COMBUSTION CHAMBER LINING OR BASEPANELS:

This product contains fiberglass jacket insulation and ceramic fiber materials in combustion chamber lining or basepanels in gas fired products. Airborne fibers from these materials have been listed by the State of California as apossible cause of cancer through inhalation.


• Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements forfiberglass wool at the time this document was written. Other types of respirators may be needed dependingon the job site conditions. Current NIOSH recommendations can be found on the NIOSH web site at http://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators, manufacturers, and phone numbers arealso listed on this web site.


■ Operations such as sawing, blowing, tear out, and spraying may generate airborne fiber concentration requiringadditional protection.




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Boiler Manual Gas-Fired Steam Boilers GSAicpindexing.toddsit.com/documents/086477/67001100400.pdf · 6 Field wiring ... Boiler Manual Gas-Fired Steam Boilers Hazards that will or