GA100CS SeriesCombination GasFired Cast IronBoiler and IndirectWater Heater

Vaillant ......Installation and

Service Manual

Table of Contents PageNumber

21. Boiler Dimensions

& Specifications2. Rules for Safe Installation 3

& Operation3. Locating the Unit 34. Combustion Air Requirements 35. Vent Pipe Connections 46. System Piping Boiler 57. Gas Supply Piping 58. Electrical Wiring 79. Flame Roll-Out 7

10. Blocked Vent System 911, Checkout Procedures 9

12. Maintenance Requirements 10

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PRICE $5.00

VaillantVaillant Corp.2607 River Road

Cinnaminson, NJ 08077(609) 786-2000Fax (609) 786-8465

All of our appliances should be installedby qualified fitters only, who will beresponsible for the observance of allexisting national and/or local installationinStructionsand code regulations.On installation please hand this pamphletto your customer.

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1. Boiler Dimensions & Specifications

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1. High Limit Control (Tank)2. Combination Control

3. Transformer Relay

4. Intermittent Ignition Control

5. Combination Pressure Temp. Gauge6. Damper Actuator7. Combination Gas Valve

8. Circulator

9. Wet Leg Drain Tappings

10. Pilot Inspection Door

11. Tank Inspection Plate

12. Water Storage Tank

13. Temperature Sensor Well

14. Air Scoop

15. Vent Valve

16. Diverting Valve

17. Expansion Tank18. Boiler drain _' NPT

19. Return 1" NPT

20. Supply 1" NPT

21. Domestic Water Out (Hot) ¾"

22. Domestic Water In (Cold) ¾"23. Gas line ½" NPT

24. Draft Diverter

25. 30 PSI A.S.M.E. Relief Valve

26. Tank Drain

27.125 PSI A.S.M.E. T&P Relief Valve

BOILER " " "- HEATING I-B-R NETINPUT WBGHT

MODEL BTU/HR CAPACITY RATING I.BS.NO. BTU/HR B'I'U/HR

GA100CS -6 60,000 ,50,000 43,000 340

GA100CS -8 80,000 67,000 58,000 360

GA100CS -10 100,000 85,000 74,000 390

2. Rules for SafeInstallation &

Operation1. Read this manual and the

Owner's Manual carefully.Failure to follow the rules for

safe operation and the instruc-tions could cause a malfunctionof the boiler and result in death,serious injury, and/or propertydamage.

2. Check your local codes andutility requirements beforeinstallation. The installationmust be in accordance withtheir directives.

3. Before servicing, allow boiler tocool and always shut off anyelectricity and gas to boilerwhen working on it. This willprevent any electrical shocks orburns.

4. Never test for leaks with openflame. Use soap suds to checkall connections. This will avoidany possibility of fire or explo-sion.

5. Be certain boiler is equipped fortype of gas (natural or propane)to be used. Over-firing will resultin premature failure of the boilersections and cause dangerousoperation.

6. Never vent this boiler into anenclosed space. Always con-nect the boiler to the outside.Never vent to another room or

inside a building.

7. Be sure there is adequate airsupply for complete combus-tion.

8. Follow a regular service andmaintenance schedule for effi-

cient and safe operation.WHEN YOUR BOILER ARRIVESBE SURE TO SAVE AND REFERTO INSTRUCTION .S_"-

First, inspect each item received forvisible damage or shortage. If anyparts are damaged, report this tothe freight company immediately,and request them to cell and makean inspection before you make anyinstallation. Have the Inspectorprepare a signed report. Send

Vaillant a copy of this report and wewill send replacements for thedamaged parts. But, we must havethe signed inspection report of thefreight company to prove theirliability.

Examine all packaging materialcarefully for loose parts beforediscarding.

Also, store all parts received wherethey will not be lost or damaged.

If you have had to unpack the boileroutside, you may also have to dis-assemble it to carry it to the installa-tion area. In this case, use the PartsList drawings herein to guide you.

NOTE: The GA1 O0 CS Series ofboilers were evaluated by theAmerican Gas Association to certifythat they meet all of the safety crite-ria of ANSI standard 7_21.13a-LatestEdition "Gas Fired Low PressureSteam and Hot Water Boilers." Safelighting and other performance crite-ria were met with the gas manifoldand control assembly provided onthe boiler when the boiler underwent

tests specified in this standard.

The following steps are all neces-sary for proper installation and safeoperation of the boiler.

1. Locating the boiler.2. Fresh air for combustion.3. Chimney & vent pipe connection.4. System piping.5. Gas supply piping.6. Electrical wiring.7. Check out and adjust.8. Maintenance.

3, Locating the UnitIf unit is to be part of an existingsystem, it is usually best to put itwhere the old one was. If you planto change location, you will needadditional material as well as anadequate base. The following rulesapply not only to replacement boil-ers, they also apply to new installa-tions:

1. The unit must be level.

2. Use a raised base if floor canbecome wet or damp.

3. The vent pipe connection shouldbe short. The center of the chim-

ney opening must be highenough to allow a '/," per ft.upward slope in vent from unitto chimney opening

4. Maintain clearances for fire safetyas well as servicing.

The room must have a total cubicfoot volume not less than 16times that of the boiler.

5. Fresh air for combustion must beavailable at the front of the boiler.

6. While this boiler may be installedon combustible flooring, it mustnot be installed on carpeting.

7. The installation must conform to

the requirements of the authorityhaving jurisdiction or, in theabsence of such requirements, tothe national Fuel Gas Code.ANSI Z223.1-Latest Edition.

8. Where required by the authorityhaving jurisdiction, the installationmust conform to AmericanSociety of Mechanical EngineersSafety Code for Controls andSafety Devices for AutomaticallyFired Boilers, No. CSD-I.

Clearance from CombustibleMaterials

The following minimum clearancesare required between boiler andcombustible construction:

Top ............................... 12 inchesRight Side ....................... 6 inchesLeft Side ......................... 6 inchesRear ................................ 6 inchesFlue Connector ............... 6 inchesHot Water Pipe ................... 1 inch

Flue and stack must be at least 6"from combustible surfaces.

If hot water pipe passes throughcombustible floors, walls, or ceil-

ings, clearance must be not lessthan ½" capped with a non-com-bustible plate (see NFPA bulletin89M, heating equipment clearance).

Servicing requirements may requirelarger clearances than thoserequired for fire safety.

As the electrical and piping connec-tions are at the rear of the unit,there should be space to permitaccess to the rear of the unit for ser-vice.

4. Combustion Air

RequirementsWARNING

Be Sure to Provide Enough FreshAir for Combustion

You must provide for enough freshair to assure proper combustion.The fire in the unit uses oxygen.The air in a house contains onlyenough oxygen to supply the bumerfor a short time. Outside air mustenter the house to replace that usedby the burner. Study the followingexamples to determine your freshair requirements.

EXAMPLE 1: UNIT LOCATION INUNCONFINED SPACE

If your unit is in an open area in aconventional house, the air thatleaks through the cracks around thedoor and windows will usually beadequate to provide air for combus-tion. The doors should not fit tightly.Do not caulk the cracks around thewindows.

EXAMPLE 2: UNIT LOCATED IN AHOUSE HAVING TIGHT CON-STRUCTION

If the house is of tight constructionwith weathemtripped windows, notenough outside air will enter for safecombustion. Install a duct or pipefrom a point near the burner to aventilated attic or crawl space or theoutside where fresh air is freelyavailable. Vertical ducts should

have a net free area of 1 squareinch for each 4,000 BTU per hourinput of all gas appliances and foreach 2,000 BTUihr. if horizontalducts are used. Screen the open-ings to keep animals and birds fromentering. This is also required if theboiler is installed near an exhaustfan or clothes dryer.

Provisions for combustion and venti-lation air in accordance with section5.3, Air for CombustTon'_ndVentilation, of the National Fuel GasCede, ANSI Z223.1-Latest Edition,or applicable provisions of the localbuilding codes.

5. Vent PipeConnections

Check Your Chlmney

This is a very important part of your

heating system. It must be clean,the dght size, propedy con_edand in good condition. No boiler canfunction properly with a bad chim-ney. If your chimney is just bigenough for your new boiler, it willnot have extra capacity for othergas appliances.

When two or more appliances arevented into the same chimney, thecress-section area inside the chim-ney must be at least equal to thearea of the largest vent PLUS ½ thearea of each additional vent.

For example, if your boiler vent hasa diameter of 5 inches (area 19.6square inches), the water heatervent, a diameter of 4 inches (12.6square inches), the minimum chim-ney area must be 19.6+ ½ of 12.6 or25.9 square inches. They willrequire a 6" diameter round chim-ney.

When removing a boiler from acommon venting system the ventingsystem is likely to be too large:forproper venting of the remainingappliances connected to it.

At the time of removal of an existingboiler, the following steps shall befollowed with each applianceremaining connected to the com-mon venting system placed in oper-ation, while the other appliancesremaining connected to the com-mon venting system are not in oper-ation.

(a) Seal any unused openings inthe common venting system.

(b) Visually inspect the ventingsystem for proper size and hori-zontal pitch and determine thereis no blockage or restriction, leak-age, corrosion and other deficien-cies which could cause an unsafecondition.

(c) Insofar as is practical, closeall building doors and windowsand all doors between the spacein which the appliances remainingconnected to the common ventingsystem are located and otherspaces of the building. Turn onclothes dryer and any appliancenot connected to the commonventing system. Turn on anyexhaust fans, such as rangehoods and bathroom exhausts,

4

so they will operate at maximumspeed. Do not operate a summerexhaust fan.

(d) Place in operation the appli-ance being inspected. Follow thelighting instructions.Adjust ther-mostat so appliance will operatecontinuously.

(e) Test for spillage at the drafthoed relief opening after 5 min-utes of main burner operation.Use the flame of a match or can-

dle, or smoke from a cigarette,cigar or pipe.

(f) After it has been determinedthat each appliance remainingconnected to the common vent-ing system propedy vents whentested as outlined above, returndoors, windows, exhaust fans,fireplace dampers and any othergas burning appliance to theirprevious conditions of use.

(g) Any improper operation of thecommon venting system shouldbe corrected so the installationconforms with the National FuelGas Code, ANSI Z223.1-LatestEdition. When resizing any por-tion of the common venting sys-tem, the common venting systemshould be resized to approachthe minimum size as determinedusing the appropriate tables inAppendix G in the National FuelGas Code, ANSI Z223.1-LatestEdition

Connect the Vent Pipe

WARNING

NEVERINSTALLA MANUALLYOPERATED DAMPER IN THEVENT PIPE OFANY GAS APPLI-ANCE.

1. Do not modify draft diverter fur-nished with the boiler.

2. Vent pipe must be same size asoutlet collar on draft diverter.

3. Slope pipe up from b_ler'to chim-ney not less than ¼" per foot.

4. Run pipe as directly as possiblewith as few elbows as possible.

5. Do not connect to fireplace flue.

6. The sections of vent pipe shouldbe fastened with sheet metal screwsto make the piping rigid. Usestovepipe wires to support the pipefrom above.

MinimumVentPipeClearanceff theventpipemustgothroughacrawlspace,doublewallventpipeshouldbeused.Whereventpipepassesthroughacombustiblewailorpartition,Usea ventilatedmetalthimble.Thethimble should be 4inches larger in diameter than thevent pipe. If boiler is installed with asingle wall galvanized type vent, itmust have 6" clearance between its

surface and any combustible materi-al. If Underwriters Laboratories list-ed type B (insulated vent pipe) isused, clearance between it andcombustible material to be as listed.

In lieu of thimble protection, all com-bustible material in the wall shall be

cut away from the vent pipe a suffi-cient distance to provide the clear-ance required from vent pipe tocombustible material. Any materialused to close up such opening shallbe non-combustible.

For boilers for connection to gasvents or chimneys, vent installationsshall be in accordance with Part 7,Venting of Equipment, of theNational Fuel Gas Cede, ANSIZ223.1--Latest Edition, or applica-ble provisions of the local buildingcodes.

Automatic Vent Damper

The GA100 Series of boilers are fit-ted with an integral vent damperwhich is operated by an actuatormounted on the front panel (SeeFig. 1).

The stack damper should bechecked for alignment and freedomof operation prior to installation andduring subsequent routine service.

6. System PipingBoiler

Place the boiler in a selected loca-

tion (as near chimne_yyas possible).Your boiler is shipped assembled.You need only to install a ¾" reliefvalve drain line. Run a pipe from therelief valve outlet to an open drain,tub or sink, or other suitabledrainage point not subject to freez-ing. Failure to do so may causewater damage or injury should therelief valve open. Pipe must be_'ame size as outlet and open end

must not be threaded.

Connect supply and return lines toboiler. The connections may requirecertain additional fittings and partsas shown on Fig. 2.

If you are replacing an old boilerwith this new one, possibly all youwill need to do is to connect theexisting piping to your boiler.

If you are installing an entire newheating system, first install all ofyour radiation units (panels, radia-tors, or cabinets) and the supplyand return mains--then make theconnection to the boiler.

When connecting the cold watersupply to the water valve, makesure that a clean water supply isavailable. When the water supply isfrom a well or a pump, a sandstrainer should be installed at the

pump.When boiler is used in connectionwith refrigeration systems, it shall beinstalled so that the chilled water ispiped in parallel with the heatingboiler with appropriate valves to pre-vent the chilled water from enteringthe heating system boiler.

The boiler piping system of a hotwater heating boiler connected toheating coils located in air handlingunits where they may be exposed torefrigerated air circulation must beequipped with flow control valves orother automatic means to preventgravity circulation of the boiler waterduring the cooling cycle.

NOTE: A hot water boiler installedabove radiation level must be pro-vided with a low water cutoff deviceat the time of boiler Installation.

It is recommended that the boiler beinstalled with gate valves on thesupply and return lines so that itmay be removed for service withoutdraining the entire system. The gatevalve on the supply pipe must notbe located between the boiler andthe relief valve or expansion tank.

Water Heater

The relief valve and drain valve forthe flow and for the hot water tank

(Fig. 2) are packed in separateboxes and mount directly to the flowand return.

If the selected temperature at thetemperature control (Fig. 1, No. 1) isin excess of 125°F a mixing valveshould be installed to minimize thedanger of scalding.

7. Gas Supply PipingINSTALL GAS PIPING AS OUT-LINED IN THE AMERICANNA't'IONAL STANDARD ANSIZ223.1-1984-- NATIONAL GASFUEL CODE FOR U.S.A. INSTAL-LATIONS

The gas pipe to your boiler shouldrun direct from the gas meter (orpropane regulator). It should supplyonly the boiler. It must be the cor-rect size for the length of the runand the boiler rating. See Fig. 3 forthe proper size. Be sure your gasline complies with local codes andthe gas company requirements.

Connecting the Gas Piping

Refer to Fig. 1 for the general layoutat the boiler. It shows the basic fit-

tings you will need. The gas lineenters the boiler from the back. The

following rules apply:

1. Use new, properly cleanedblack iron piping and fittings,free from chips.

2. Apply good quality pipe dope topipe only, leaving 2 end threadsbare.

3. Install a sediment trap to trapdirt and moisture before it canenter the boiler.

4. Install a manual shut-off valve invertical pipe about 5 feet above,floor (not supplied by Vaillant).

5. Tighten all joints securely.6. Propane gas connections

should only be made by alicensed propane installer.

7. The boiler and its individualshut-off valve must be discon-nected from the gas supply pip-ing system during any.pressuretesting of that system at testpressures in excess of ½ psig.

8. The boiler must be isolated from

the gas supply piping system byclosing its individual manualshutoff valve during any pres-sure testing of the gas supplypiping system at test pressureequal to or tess than ½psig(3.5KPa).

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the supply side of theheating circuit as closeas is possible to thethree way valve. Thiswill minimize the chance

of waterhammePoocuring.

CAUTION: When storage tank is above 125°F a mixing valve should be installedto minimize the chance of scalding.

F,ig. 2 - Typical Piping Arrangements

Checking the Gas Piping

Upon completion of piping, chockright away for gas leaks. Open themanual shut-off valve. Test for leaks

by applying soap suds (or a liquiddetergent) to each joint. Bubblesfoaming indicate a leak.

CORRECT EVEN THE SMALLESTLEAK AT ONCE.

WARNING

NEVER USE A MATCH OR OPENFLAME TO CHECK FOR LEAKS.

LENGTHOF PiPE

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NATURAL GAS

PiPE CAPACITYCUBIC FEET/HOUR

_" ¾" 1" 1_"

20 74 150 280 580

40 50 100 195 400

60 40 84 155 320

80 34 72 135 275

Fig. 3 - Gas Pipe Capacities

MODEL GA100 CS -60 -80 -100

Elevation

Sea level to 2,000 ft. 38 42 38

2,000 to 5,000 ft. 40 43 41

5,000 to 7,000 ft. 41 44 42

7,000 to 9,000 ft. 42 46 43

9,000 to 10,000 ft. 43 47 44

Fig. 4 - Orifice Size for Natural Gas

MODEL GA100 CS -60 -80 -100

Elevation

Sea level to 2,000 ft. 52 53 52

2,000 to 5,000 ft. 53 55 53

5,000 to 7,000 ft. 53 55 53

7,000 to 9,000 ft. 55 56 54

9,000 to 10,000 ft. 55 56 54

Fig. 5 - Orifice Sizefor Propane (LPG)

Orifice Sizing

All Vaillant GA100 CS series unitsare factory equipped with orificessized for installation at elevationsranging from sea level up to 2,000feet. For higher elevations, smallerorifices are required to assure safeoperation. Order the proper orifices

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from your supplier and install them

before turning boiler on. See Figs. 4&5.

8. Electrical WiringInstall Your Thermostat.

The thermostat location has animportant effect on the operation ofyour boiler system. BE SURE TOFOLLOW THE INSTRUCTIONSINCLUDED WITH YOUR THERMO-STAT.

Locate the thermostat about fivefeet above the floor on an insidewall. It may be mounted vertically onthe wall or on a vertically mountedoutlet box. It should sense averageroom temperature, so avoid the fol-lowing:

Dead Spots:

1. Behind doors2. Corners and alcoves

Hot Spots:

1. Concealed pipes2. Fireplaces3. TV sets4. Radios

5. Lamps6. Direct sunlight7. Kitchens

Cold Spots:

1. Concealed piping or ducts2. Stairwell drafts3. Door drafts4. Unheated rooms on other side

of wall

Control Wiring Diagrams

Field Wiring and Wire Replacement

in the following wiring diagramsdashed lines .... represent fac-tory wiring 24V; dashed lines• • • represent field wiring 24V;solid lines -- represent factorywiring 120V; solid lines _ rep-resent field wiring 120V.

Field wiring, whether for a newinstallation or to replace damagedfield or factory installed widng, mustbe the type listed below, and mustbe installed in accordance with theNational Electric Code and all other

codes and standards covering theboiler installation.

120-Volt Wiring

All new and replacement wiringmust be U.L. listed and 14-gaugesize (minimum). Install wire inapproved conduit. All terminals andsplices must be in a listed coveredbox.

If an external electrical source is uti-lized, the boiler, when installed,must be electrically ground in accor-dance with the requirements of theauthority having jurisdiction or, inthe absence of such requirements,with the National Electrical Code,ANSI/NFPA No. 70-Latest Edition.

24-Volt (Low Voltage) Wiring

Use listed low-voltage cable. Alljunctions must be clean, joined firm-ly, and suitably covered with electri-cal tape or approved wire connec-tors.

9. Flame Roll OutThe GA100 CS Series is equippedwith a Flame Roll-Out Safety Shut-Off System. The system is designedto shut off the boiler if a blockageoccurs in the heat exchanger thatcauses flames to roll-outthe bottomof the burner tray. Temperature acti-vated switch is located on a bracket

next to the pilot or ignitoron theunderside of the burner tray.

When corrective action has beentaken to eliminate the restrictionthe pre-set switch has to bereplaced with a Vaillant suppliedreplacement.

10. Blocked Vent

SystemThe GA100 CS Series is equippedwith a =BlockedVent Shut-Off

System'. This system relies on atemperature sensitive-6witch locatedon the side of the draft hood. If the

vent pipe or chimney shouldbecome obstructed to the point ofnot completely evacuating the fluegases, the switch will break andclose down the unit.

When the vent or chimney restric-tion has been removed, the switchcan be reset.

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11. CheckoutProcedures

Test for Any Gas Leaks

Inspect carefully all gas connectionsfor gas leaks before lighting bumer.Do not check for leaks with anopen flame.

Test for leaks with a soap solutionmade of 2 tablespoons of flake,granular, or liquid soap mixed wellwith _ cup of warm water andspread generously on connection inquestion, using a brush or cloth.

For Your Safety ReadBefore Operating

WARNING

IF YOU DO NOT FOLLOWTHESE INSTRUCTIONS EXACT-LY, A FIRE OR EXPLOSION MAYRESULT CAUSING PROPERTYDAMAGE, PERSONAL INJURYOR LOSS OF LIFE.

A. This appliance is equipped withan ignition device which automati-cally lights the burners. Do not tryto light the pilot by hand.

B. Before operating smell all aroundthe appliance area for gas. Besure to smell next to the floor

because some gas is heavierthan air and will settle on thefloor.

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 yourbuilding.

• Immediately call your gas sup-plier from a neighbor's phone,follow the gas supplier's instruc-tions.

• If you cannot.r.ea_,byour gassupplier, call the FireDepartment.

C. Use only your hand to push in orturn the gas control knob, neveruse tools. If the knob will not pushin or turn by hand, don't try to

repair it, call a qualified servicetechnician. Force or attemptedrepair may result in a fire orexplosion.

Operating Instructions1. STOP! READ THE SAFETY

INFORMATION.

2. Set room thermostat to lowest

temperature.

3. Turn off electric power.

4. Turn gas cock knob clockwiseand turn to OFF. Wait five min-utes, then turn knob to latchposition at ON.

5. Turn on electric switch. Burnershould turn on when thermostat isset above room temperature.

Reset Ignition System

1. Turn the thermostat to the low

end of its temperature range.2. Turn the electric switch to the

OFF position.

3. Wait 5 minutes, then turn thesystem switch to ON position setthe thermostat at least 4°F

(2.2°C) above room temperature.The boiler should start. If theabove steps do not start the pilotand main burner, call your gasappliance service technician, donot attempt to light manually.

To Turn Off Gas To Appliance

1. Set the thermostat to lowestsetting.

2. To shut off burner manually, turngas cock knob clockwise F'_and turn to OFF position.

3. Turn off electric switch.

Adjustment of Gas Input--NaturalGas

To check for proper flow of gas intocombustion chamber, determine theBTU/hr. input from the instructionplate on the jacket. Divide this inputby the BTU per cubic foot of avail-able gas to get the required numberof cubic feet of gas per hour.

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Determine flow of gas through thegas meter for 2 minutes and multiplyby 30 to get the hourly flow rate.Turn off all other gas equipmentconnected to meter when makingthis test.

Manifold pressure should be set toabout 4" W.C. for natural gas. Smallvariations in gas flow may be madeby means of the gas pressure regu-lator adjustment. However, the finalmanifold pressure setting should notvary more than plus oTmlhus 0.3"from the 4" valve. Any necessarymajor changes in the flow should bemade by changing the size of theburner orifice.

Safety Check of Controls

After boiler has been hooked up andis ready for operation, a few simplechecks should be made to be sureall controls are functioning properly.

1. Thermostat--Turn thermostat tohighest setting. This should turnon the main burner. Adjust heatanticipator to proper current draw.

2. Thermocouple--The pilot lightsthe main burner on demand andprovides a safety feature througheither a single couple thermocou-pie or multiple couple thermocou-pie which is placed in the pilotflame. These thermocouples gen-erate a small amount of electricitywhich permits the valve to openonly when the pilot is burning. Tocheck the thermocouple for safeoperation, ignite the main burner,then disconnect the thermocouplelead. The main burner shouldshut off.

3. Limit--The limit turns off theburner when the boiler water tem-perature reaches the temperaturesetting of the limit. To check this,set the limit at a lowest settingand let the burner run until thelimit turns it off. Raise tempera-ture setting of limit.This shouldturn on burner.

Relief Valve

You have a safety relief valve onyour boiler. It will automatically openat 30 psig pressure. This will relievethe strain on the boiler and system.Run a pipe from the relief valve out-let (pipe must be same size as out-let and open end must not bethreaded) to an open drain, tub orsink, or other suitable drainage pointnot subject to freezing. Failure to doso may cause water ci_mage orinjury should Relief Valve release.

Main Burner

The main burner flame can beobserved through the inspectiondoor (Fig. 7). The flame should betranslucent and blue in color. The

presence of any yellow streakingwould indicate the presence of dustor lack of primary air. A vacuumcleaning of the burner tray and com-bustion area is indicated.

DOOR _

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Checks for Electronic Ignition

The probe lead connections tosensing probe and control terminalmust be secure. Electrodes shouldhave a spark gap of '/a". If the pilotburner does not ignite, check to seethat all connections are proper.

Observe presence of spark. If sparkis not present, determine if power isavailable to the control. The ignitioncontrol should be replaced if, withpower applied and spark gap prop-erly set at _", sparking does notoccur. If pilot gas does not lighteven though a spark is present, gasis not available at the pilot burner orthe gas pressure is too low or high.If pilot ignites, but burner does not,check probe lead connections to thesensing probe and control. Do notattempt to field repair the control.Replace defective controls.

12. Maintenance

RequirementsCLEANING MUST INCLUDE PERI-ODIC EXAMINATION OF VENTINGSYSTEMS. ALL FLUE GAS PAS-SAGEWAYS FROM BOILER TOCHIMNEY AND THE CHIMNEYITSELF SHOULD BE INSPECTEDAND CLEANED IF NECESSARY.THIS SHOULD BE PERFORMEDAT LEAST ONCE A YEAR, PRIORTO THE STARTING OF THEHEATING SEASON.

1. Brush entire surface of all fluesusing a long handled wire brush.Remove all soot, rust and scalefound. Inspect with a flashlight tosee that all flueways are com-pletely open. Remove soot anddirt from bottom of boiler.

2. Inspect the flue cover, draftdiverter, and smokepipe andreplace unserviceable parts,clean all soot, rust or scale fromthese parts and from chimney.Clean the burners; use a soapsolution if necessary.

CAUTION: If it becomes necessaryto remove the draft diverter, it mustbe rasealed to the casting usingnew sealant to be sure no fumes

can escape.

3. Reassemble all parts and startthe boiler following the installationinstructions. Carefully inspect fireabove each burner for a stableand blue flame. Carbon monoxide

poisoning can be caused by yel-lowish unstable (wavy) flame.

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;urnerCleaningurnersshouldbeinspectedafterachboilercleaning.Slots(ports)anbebrushedfreeofdirtandlint,ith a stiff bristle brush. Do notamage metal at ports. The pilotnd thermocouple or pilot generator

should be brushed free of dirt. Takecare not to damage pilot, bend it outof position, or to plug pilot gas port.

Maintained Inspection

The homeowner and service per-sonnel must, at all times, be alertedfor these items:

1. Gas odor.

a) Open the windows.b) Do not touch any electrical

switch.

c) Extinguish any open flame,if possible.

d) Shut off the main gas valve.e) Call the gas supplier.

2. Excessive heat, odors, smoke,unusual noise. Shut off gas toall appliances and call gas sup-plier or Fire Department andservice organization.

3. Keep area around the boilerclean and free from combustible

materials, gasoline and otherflammable vapors and liquids.

4. Make allowances and maintainfree flow of combustion andventilating air.

Freeze Protection

If the boiler is taken out of service

during potentially freezing weather,always DRAIN IT COMPLETELYsince any water left in the boiler orpipes can freeze and cause dam-age. Be sure to open drain cocks onthe wet legs of the left and rightcastings, see Fig. 1.

Pilot and Burner

Check for proper pilot flame asexplained in "Checkout Procedures'on page 9.

Burner Portsand Slots 4- 3/.. -..-,/.. ±'/."

PilotBracketMountedon Burner Panel ForUse withNatural

& Propane Gas

Pilot and Burner Assembly - GA100 -60 Thru GA100 -100 E.I.

Fig. 9 - Electronic Ignition

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VaillantVaillant Corp.2605-07 River Road

Cinnaminson, NJ 08077(609) 786-2000

mBooklet No.:2180-0113