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GSA

 

Gas-Fired Steam Boilers – 

Boiler Manual

5

Part Number 550-110-738/1012

Figure 2

  Terminations with Type B 

vent fitted with 

listed cap,  

provided vent is at least 8 feet from 

any vertic

al 

wall or similar obstruction locations

1  Prepare boiler location  

continued

Air contamination

Please review the following information on potential combustion 

air contamination problems.
See Table 2 for products and areas which may cause contaminated 

combustion air.

  To  prevent  potential  of  severe  personal  injury  or 

death,  check  for  products  or  areas  listed  below 

before installing boiler. If any of these contaminants 

are found:
•  Remove contaminants permanently.

 

 

 

— OR —

 

•  Isolate boiler and provide outside combustion 

air. See national, provincial or local codes for 

further information.

Table 2 

Corrosive contaminants and likely locations

Vent System

Chimney or vent requirements

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

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

codes.  Canadian  installations  must  comply  with  B149.1  or 

B149.2 Installation Codes.

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

Chimney or vent termination:
•  A chimney,  or any vent other than a Type B vent with listed 

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

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

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

horizontal distance of 10 feet.

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

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

obstruction.

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

above the roof penetration and at least 2 feet higher than 

any portion of a building within 10 feet.

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

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

and  ordinances. Vitreous  tile  linings  with  joints  that  prevent 

retention  of  moisture  and  linings  made  of  noncorrosive 

materials are best. Advice for flue connections and chimney 

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

wall metal vent pipe or single-wall vent pipe may be used as 

a liner.

4.  Cold  masonry  chimneys,  also  known  as  outside  chimneys, 

typically have one or more walls exposed to outside air. 

When any atmospheric gas-fired boiler with automatic vent 

damper is vented through this type of chimney, the potential 

exists for condensation to occur. Condensation can damage a 

masonry chimney. The following are recommended to prevent 

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

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

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

b.  Provide drain trap to remove any condensate.

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

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

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

outlet area of additional appliances. 

Products to avoid

Spray cans containing chloro/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
Buildings under construction (where air is contaminated with 

particulates)

Summary of Contents for GSA-075

Page 1: ... property damage INSTALLER Read all instructions before install ing Read page 2 first Follow all instructions in proper order to prevent personal injury or death Consider piping and installation when determining boiler location Any claims for damage or shortage in shipment must be filed immediately against the transporta tion company by the consignee GSA boilers cannot be adapted for heater use Ha...

Page 2: ...ing or sealing compounds in boiler system Water seal deterioration will occur causing leakage between boiler sections circulator flanges diaphragm tanks or other system components This can result in substantial property damage 7 DO NOT use homemade cures or boiler patent medicines Serious damage to boiler personnel and or property may result 8 Continual fresh makeup water will reduce boiler life M...

Page 3: ...s to boiler and system components 2 Clearances to Type B vent materials are as specified by the vent manufacturer Alcove not closet installations only GSA boilers are not approved for closet installation only for alcove installation with minimum clearances to combustible surfaces as shown in the table at right See Figure 1 The front side must be completely open that is a 3 walled room Clearance fo...

Page 4: ... Place in operation the appliance being inspected Follow the operating instructions Adjust thermostat so appliance will operate continuously e Test for spillage at draft hood relief opening after 5 min utes of main burner operation Use the flame of a match or candle f After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as out...

Page 5: ...eous tile linings with joints that prevent retention of moisture and linings made of noncorrosive materials are best Advice for flue connections and chimney linings can be obtained from local gas utility Type B double wall metal vent pipe or single wall vent pipe may be used as a liner 4 Cold masonry chimneys also known as outside chimneys typically have one or more walls exposed to outside air Wh...

Page 6: ...gs gasketed AND Weather stripping has been added on openable windows and doors AND Caulking or sealants are applied to areas such as joints around windows and door frames between sole plates and floors between wall ceiling joints between wall panels at penetrations for plumbing electrical and gas lines and in other openings Tight construction requirements If building is of tight construction and a...

Page 7: ...ll could expand and cause excessive pressure resulting in severe personal injury death or substantial property damage 2 Check for stable gauge pressure for more than 10 minutes Visually check for leaks if gauge pressure drops Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to boiler will result causing substantial property damage 2 Retest boiler after repair...

Page 8: ...stantial property damage 7 Install rollout thermal fuse element with wire termi nals facing up on front access panel as shown in Figure 10 Wire per the appropriate Control Supple ment Inspect burners GSA 300 boiler 1 All units except GSA 300 are factory assembled but the burners and base panels should be inspected to ensure they are in good condition 2 Remove the access panel Figure 10 and inspect...

Page 9: ... CSA certification will become void Flue gas spillage and carbon monoxide emissions will occur causing severe personal injury or death Screw 10 32 x 3 8 Screw 6 x Boiler cement Access panel Rollout TFE 63904 GSA GSA 300 P Burner Pilot burner Pilot Legend P Figure 10 Access panel Figure 9 Burner drawer installation Figure 8 Burner and pilot burner location Figure 7 Burner drawer assembly Figure 6 F...

Page 10: ...his dimension Do not modify draft hood or vent damper or make another connection between draft hood and vent damper or boiler except as noted below This will void CSA certification and will not be covered by warranty Any changes will cause severe personal injury death or substantial property damage 2 Prepare boiler continued 5 Plug damper harness receptacle into damper harness plug Bypassing jumpe...

Page 11: ...e conden sate return is not adequate refer to recommendations on page 13 Figure 12 Recommended piping piping for parallel flow systems only see Table 6 for recommended sizing Table 6 Recommended pipe sizing Connecting to counterflow piping Apply the recommended piping in Figures 12 and 14 only when connecting to a parallel flow system When connecting to a counterflow system the boiler steam supply...

Page 12: ...ons including the valve inlet are clean and free from any foreign matter Mount the relief valve only in the vertical position directly connected to the tapping designated in the manual on top of the boiler Use pipe compound sparingly or tape on external threads only Do not use a pipe wrench Use proper type and size wrench on wrench pads only Install relief valve in tapping on top of boiler See Tab...

Page 13: ...Measure length of time from when condensate begins to return to when it stops returning Divide this time by 2 5 Add time measured in step 3 to time calculated in step 4 This sum is the average time required for condensate to return to the boiler 6 If this total time is 10 minutes or less no reservoir pipe is needed If total time for condensate to return to boiler from step 5 is more than 10 minute...

Page 14: ... Supple ment Figure 15 Controls Float type low water cutoff when provided by others 1 Install low water cutoff as shown in Figure 16 below SeeTable 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 to eliminate potential of severe burns Do not plug v...

Page 15: ...ly to male threads of pipe joints so that pipe dope does not block gas flow Failure to apply pipe dope as described in this manual can result in severe personal injury death or substantial property damage Table 9 Pipe capacity for 0 60 specific gravity natural gas Natural Gas 1 See Table 9 for pipe length and diameter Base on rated boiler input found on page 31 divide by 1 000 to obtain cubic feet...

Page 16: ... and any local codes Wiring connections Boiler is shipped with controls completely wired except spill switch and vent damper See wiring diagram in the GSA Spark Ignition Control Supplement Thermostat 1 Connect thermostat as shown on wiring diagram on boiler 2 Install on inside wall away from influences of drafts hot or cold water pipes lighting fixtures television sunrays or fireplaces 3 If thermo...

Page 17: ...l except for leakage tests until boiler is ready to be fired 2 Fill to normal waterline halfway up gauge glass 3 Boiler water pH 7 0 to 8 5 is recommended 4 Follow skimming procedure right Skimming the boiler Clean all newly installed steam boilers to remove oil and grease Failure to properly clean can result in violent fluctuations of water level water passing into steam mains or high maintenance...

Page 18: ...and repair immediately 2 Inspect vent system thoroughly for signs of deterioration from corrosion physical damage or sagging Verify that masonry chimney liners are in good condition with no obstructions and there are no openings into the chimney 3 Check around the boiler for gas odor following the procedure of Check for gas leaks page 17 4 Verify operation using procedures below Perform Checkout p...

Page 19: ...er operation 1 Raise room thermostat to call for heat Vent damper actuator will slowly open vent damper 2 When vent damper is fully open Main gas valve will open and main burners will ignite Vent damper must be fully open before main burn ers light If vent damper does not fully open flue products such as carbon monoxide will escape into house causing severe personal injury or death 3 Lower thermos...

Page 20: ...____________________________ ______________________________ company address phone _____________________________________ installer s signature o Installation instructions have been followed o Check out sequence has been performed o Above information is certified to be correct o Information received and left with owner maintenance person Spark ignition boilers Connect manometer to outlet side of gas...

Page 21: ...terline 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 Follow the Service and maintenance procedures given...

Page 22: ...cted under Section 7 page 17 of this manual o Inspect 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 damage to boiler will occur resulting in substantial property damage Eliminate all system or boiler leaks Continual fresh makeup water will reduc...

Page 23: ...le test per page 15 of this manual if there is any indication of a leak Boiler waterline Normal waterline is halfway up gauge glass Limit controls 1 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 o Check test Low water cutoffs Probe type low water cutoff see below Clean probe type...

Page 24: ...ng 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 be performed at the end of any non service period Follow the instructions below for a try lever test With the system at operating pressure lift and hold the test lever fully open for at least 5 seco...

Page 25: ...al n Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid n Eye Irrigate immediately n Breathing Fresh air This product contains fiberglass jacket insulation and ceramic fiber materials in combustion chamber lining or base panels in gas fired products Airborne fibers from these materials have been listed by the State of Califor...

Page 26: ...ass and 1 each 3 and 6 square cut seals 381 800 100WT 10 End section right hand 18118 311 800 029WT 11 Intermediate section 1815 311 800 010WT Item number Description Part number 12 Tie rod 1 2 GSA 075 GSA 100 GSA 125 GSA 150 GSA 175 GSA 200 GSA 250 GSA 300 560 234 470WT 560 234 475WT 560 234 480WT 560 234 485WT 560 234 490WT 13 Front base panel insulation in Base insulation kit 14 Base access pan...

Page 27: ...800 155WT 421 800 156WT 3 Jacket panel right side 421 800 151WT 4 Jacket panel door GSA 075 GSA 100 GSA 125 GSA 150 GSA 175 GSA 200 GSA 250 GSA 300 421 800 167WT 421 800 168WT 421 800 169WT 421 800 170WT 421 800 171WT 5 Jacket panel interior GSA 075 GSA 100 GSA 125 GSA 150 GSA 175 GSA 200 GSA 250 GSA 300 421 800 162WT 421 800 163WT 421 800 164WT 421 800 165WT 421 800 166WT 6 Jacket panel rear GSA ...

Page 28: ...GSA Gas Fired Steam Boilers Boiler Manual 28 Part Number 550 110 738 1012 10 Replacement parts continued Figure 22 Controls and trim ...

Page 29: ...GSA Gas Fired Steam Boilers Boiler Manual 29 Part Number 550 110 738 1012 10 Replacement parts continued Figure 23 For Spark Ignition Gas Controls see GSA Spark Ignition Control Supplement ...

Page 30: ...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 125 3 2 1 2 61 2 6 21 505 GSA 150 3 2 1 2 61 2 6 21 505 GSA 175 3 2 1 2 9 7 25 585 GSA 200 3 2 1 2 9 7 25 585 GSA 250 3 2 3 4 91 2 8 29 660 GSA 300 3 2 3 4 Note 3 Note 3 34 735 Note 2 Size gas piping from meter to boiler per local utility req...

Page 31: ...0 157 500 131 000 454 109 000 11 2 82 8 7 I D x 20 GSA 200 200 000 167 000 180 000 150 000 521 125 000 11 2 82 8 7 I D x 20 GSA 250 250 000 209 000 225 000 188 000 654 157 000 12 6 83 0 8 I D x 20 GSA 300 299 000 247 000 270 000 216 000 770 185 000 14 0 82 4 8 I D x 20 Notes 1 Based on standard test procedures prescribed by the United States Department of Energy 2 Net AHRI ratings are based on net...

Page 32: ...32 Part Number 550 110 738 1012 W T 8201 W Calumet Rd Milwaukee WI 53223 GSA Gas Fired Steam Boilers Boiler Manual ...

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