Calumet GSA Manual Download Page 1

Part Number 550-110-738/0703

G SA

This manual must only be used by a 

qualified heating installer/service technician.

 Failure to comply could result in

severe personal injury, death or substantial property damage.

When calling or writing about the boiler— Please have:  •  boiler model number from the boiler rating label  and    •  CP number
from the boiler jacket. You may list the CP number in the space provided on the “Installation and service certificate” found on
page 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 injury

or property damage.

Special instructions on installation, operation or
maintenance that are important but not related to
personal injury or property damage.

INSTALLER 

 Read all instructions before

installing. 

Read page 2 first

. Follow all instructions

in proper order to prevent personal injury or death.

• Consider piping and installation when determining

boiler location.

• Any claims for damage or shortage in shipment

must be filed immediately against the transportation
company by the consignee.

• GSA boilers cannot be adapted for heater use.

Hazards that 

will cause severe

 personal injury,

death or substantial property damage.

Hazards that 

can cause severe

 personal injury,

death or substantial property damage.

Hazard definitions

USER 

— Please read the following. Failure to

comply could result in severe personal injury, death
or substantial property damage.

This manual is for use only by your qualified
heating installer/service technician

.

• Please see the User’s Information Manual for your

reference.

• Have the boiler serviced by a qualified service

technician, at least annually.

Summary of Contents for GSA

Page 1: ...ersonal injury or property damage Special instructions on installation operation or maintenance that are important but not related to personal injury or property damage INSTALLER Read all instructions...

Page 2: ...ubstantial 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 mai...

Page 3: ...e room must provide the following minimum clearances in all directions to the boiler and components Jacket and flue collector sides rear 6 inches Jacket front 18 inches Vent pipe other than Type B ven...

Page 4: ...ons will occur causing severe personal injury or death Inspect existing chimney before installing boiler Failure to clean or replace perforated pipe or tile lining will cause severe personal injury or...

Page 5: ...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...

Page 6: ...cation continued Exhaust fans and air movers The appliance space must never be under a negative pressure Always provide air openings sized not only to the dimensions required for the firing rate of al...

Page 7: ...upward at least per lineal foot toward chimney or vent and support with hangers to prevent sagging 4 Breeching must not be connected to any portion of a mechanical draft system that can operate under...

Page 8: ...th 3 8 diameter hole in vent damper hole Minimum clearances Provide a minimum of 6 between the vent damper and any combustible material See Minimum clearance to combustible materials page 3 for minimu...

Page 9: ...3 3 1 Note 24 minimum from waterline to header Figure 5 Recommended piping piping for parallel flow systems only Connecting to counterflow piping Apply the recommended piping in Figures 4 through 7 on...

Page 10: ...arge amounts of steam and or hot water Therefore to reduce the potential for bodily injury and property damage a discharge line MUST be installed that Is connected from the outlet to a safe point of d...

Page 11: ...ar floor close to floor drain to eliminate potential of severe burns Do not plug valve or place any obstruction in blowdown line 3 Water feeders are not recommended for primary control A low water cut...

Page 12: ...n cap and tee b Install ground joint union for servicing when required c Install manual shutoff valve in gas supply piping outside boiler jacket when required by local codes or utility requirements d...

Page 13: ...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 connections Boiler is shipped with controls...

Page 14: ...ease Failure to properly clean can result in violent fluctuations of water level water passing into steam mains or high maintenance costs on strainers traps and vents Do not use petroleum based cleani...

Page 15: ...ning or sealing compounds in boiler system Severe damage to boiler will occur resulting in substantial property damage 1 Check system piping for leaks If found shut down boiler and repair immediately...

Page 16: ...installed controls If boiler has an additional high limit low water cutoff or other controls test for operation as outlined by manufacturer Burners should be operating and should go off when controls...

Page 17: ...ighted following the Lighting Instructions in this manual and on boiler Vent damper will remain closed until a call for heat 2 Call for heat When thermostat circuit closes the boiler vent damper is en...

Page 18: ...the appliance 5 When equipped with Johnson Controls vent damper Model M35 manually rotate damper blade in direction of arrow to Open position indicated on damper assembly 6 Turn gas control knob clock...

Page 19: ...nspect the appliance and to replace any part 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...

Page 20: ...Service and maintenance Service technician see following pages for instructions Owner maintenance see User s Information Manual for instructions A NNNUAL START UP Inspect Reported problems Boiler area...

Page 21: ...Piping 1 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 sealing compounds in boiler system Severe...

Page 22: ...per on page 15 2 Check gas piping per pages 12 and 14 verifying no indications of leakage and all piping and connections are in good condition 3 Read the Lighting Instructions page 18 or 19 whichever...

Page 23: ...the heating season to verify the valve and discharge piping flow freely If corrosion and or deposits are noticed within the valve body testing must be performed more often A try lever test must also...

Page 24: ...ns pages 18 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 obtai...

Page 25: ...to closed position Close thermostat contacts Vent damper will rotate to open position Is 24VAC present across gas valve terminals Remove damper harness from damper harness plug TEMPORARILY install jum...

Page 26: ...n assembly flue collector draft diverter vent damper and base assembly 13 Replacement parts The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instru...

Page 27: ...738 0703 Figure 17 Jacket assembly 13 Replacement parts continued The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on page 32 of this...

Page 28: ...GSA Gas Fired Steam Boilers Boiler Manual 28 Part Number 550 110 738 0703 Figure 18 Controls and trim 13 Replacement parts continued...

Page 29: ...GSA Gas Fired Steam Boilers Boiler Manual 29 Part Number 550 110 738 0703 13 Replacement parts continued Figure 19 Gas controls...

Page 30: ...Gas connection manifold size Note 2 inches NPT V Damper height inches D Vent diameter inches W Jacket width inches Approximate shipping weight GSA 075 3 2 1 2 6 5 17 430 GSA 100 3 2 1 2 6 5 17 430 GSA...

Page 31: ...nts 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 allowance should be made for unusual piping and pic...

Page 32: ...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 Ai...

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