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CONTENTS .........................................................................PAGE
Dimensions............................ ......................................................2
Installation Requirements:

Boiler Location........................................ ................................3
Boiler Foundation....................................................................3
Chimney Requirements............................. .............................3

Minimum Clearance.....................................................................3

Vent Piping..............................................................................4

Gas Piping............................................. ......................................4

Electrical Controls and Wiring.................... ............................5
Boiler Room Air Supply and Ventilation......... .........................5
Draft Hood Installation.............................. ..............................5
Piping at Boiler—Water Boilers................... ...........................6
Steam Controls Assembly and Installation .............................6
Piping a  Steam Boiler .........................................................6,7
Vent Damper.......................................... ..............................8,9

Operating Instructions:

Filling and Venting Water Systems.............. ...........................9
Initial Start, Safety and Lighting Instructions... ................10-11
Burner Adjustment, Checking Gas Input...... ........................12
Controls, Safety Check .........................................................13

Low Water Cut-off Check-Out....................................................13
Pressure Control Check-Out .....................................................13
Blowing Off a Steam Boiler........................................................14
Care and Maintenance.................................. ............................15

Safety Check for Control System..........................................16
Protection From Freezing.......................... ...........................16
Water Treatment....................................................................16

Sequence of Operations............................................................17
Wiring Diagrams.......................................... .........................18-25
Pump or Valve Zoning—Water Boilers.............. ........................26
Troubleshooting Guide...............................................................27
Piping a Heating and Cooling System.......................................28
Replacement Parts...................................... ..............................28
Appendix A ................................................................................29

IMPORTANT

READ ALL OF THE FOLLOWING WARNINGS AND

STATEMENTS BEFORE READING THE 

INSTALLATION INSTRUCTIONS

WARNING

LIQUEFIED PETROLEUM (L.P.)

PROPANE GAS-FIRED BOILERS

Installation location ONLY as permitted in paragraph entitled
"LIQUEFIED PETROLEUM (L.P.) PROPANE GAS-FIRED
BOILER  LOCATION" on page 3 of this instruction book.
The above warning does not apply to NATURAL gas-fired boilers.

The installation must conform to the requirements of the authori-
ty having jurisdiction or, in the absence of such requirements, to
the National Fuel Gas Code, ANSI Z223.1-latest edition. The
installation must also conform to the additional requirements in
this Slant/Fin Instruction Book.

In addition, where required by the authority having jurisdiction,
the installation must conform to American Society of Mechanical
Engineers Safety Code for Controls and Safety Devices for
Automatically Fired Boilers, No. CSD-1.

This manual must be left with owner and should be hung on or
adjacent to the boiler for reference.

WARNING

This boiler, gas piping and accessories must be installed, con-
nected, serviced and repaired by a trained, experienced service
technician, familiar with all precautions required for gas-fired
equipment and licensed or otherwise qualified, in compliance
with the authority having jurisdiction.

Printed in U.S.A. 706

PUBLICATION GG-40

Part No. 41-0549

Rev. I

INSTALLATION AND OPERATING INSTRUCTIONS

HOT WATER—Models GG-75H through GG-399H
LOW PRESSURE STEAM AND HOT WATER—

Models GXH-105 through GXH-300H and Models GX-225 and GX-250

LOW PRESSURE STEAM—Models GXHA-100 through GXHA-200

GALAXY

GAS-FIRED CAST IRON BOILERS FOR NATURAL AND L.P. PROPANE GASES

Heating Contractor

Address

Phone Number

Boiler Model Number

Boiler Serial Number

Installation Date

Summary of Contents for GG-100H

Page 1: ...his instruction book The above warning does not apply to NATURAL gas fired boilers The installation must conform to the requirements of the authori ty having jurisdiction or in the absence of such requirements to the National Fuel Gas Code ANSI Z223 1 latest edition The installation must also conform to the additional requirements in this Slant Fin Instruction Book In addition where required by th...

Page 2: ... 4 91 4 91 4 91 4 91 4 GXHA 100 GXH 105 GXHA 120 GXH 125 GXH 150 GXHA 160 GXH 170 GXH 190 GXHA 200 GXH 210 GX 225 GXH 230 GX 250 GXH 250 GXH 275 GXH 300H A 23 23 261 2 261 2 261 2 293 4 293 4 293 4 293 4 321 2 321 2 321 2 B 161 2 161 2 161 2 161 2 20 20 20 20 231 4 231 4 231 4 231 4 231 4 26 26 26 C 5 5 5 6 7 6 7 7 7 7 8 7 8 7 7 9 D 463 8 531 4 551 2 551 2 551 2 551 2 565 8 551 2 565 8 551 2 551 2...

Page 3: ...Code Local codes apply If a masonry chimney is exposed to the outdoors on one or more sides below the roof line exterior chimney ONE of the following options apply 1 Chimney must be re lined with a UL LISTED metallic liner When this is done the chimney will be considered NOT exposed to the outdoors and the requirements of the National Fuel Gas Code for NON exposed chimneys and or local codes will ...

Page 4: ...as 1 Measure or estimate the length of piping from the meter to the installation site 2 Consult gas supplier for heating value of gas BTU cu ft 3 Divide boiler rated input by heating value to find gas flow in piping cu ft per hour 4 Use table below to select proper pipe size Example Boiler model GG 300 is to be installed Distance from gas meter to the boiler is 50 ft Heating value of natural gas i...

Page 5: ... for air under various conditions Local codes may specify minimum opening sizes and locations The following recommendation applies to buildings of energy saving construc tion fully caulked and weather stripped Provide one GRILLED opening near the floor and one near the ceiling on an outside wall near the boiler or duct from such openings to the boiler EACH opening to be a minimum of one square inc...

Page 6: ...ir vents should be located fifteen inches from the drip and if possible eight inches above the pipe so that water hammer does not damage the vent and render the vent inoperable For more information on air vents check with any manufac turer of steam accessories steam traps boiler feed pumps air vents etc 5 Process water applications involving steam boilers requires Attach the hood to the boiler flu...

Page 7: ...RTFORD LOOP See Note No 1 on page 6 FIGURE 1 A Hartford Loop is recommended for low pressure steam systems with gravity condensate returns Pipe sizes shown above for Hartford Loop are recommended by Slant Fin However certain local codes may require larger pipe sizes Consult with local authorities The equalizer should be full size from the steam supply to the operating water level Hot water fill is...

Page 8: ...UG as described in the installation instructions and the vent damper installation and checkout procedures have been completed Failure to observe this warning may create a haz ardous condition that could cause an explosion or carbon monoxide poisoning B 1 This device must be installed after the appliance draft hood between the draft hood outlet and the connector to the outdoor chimney or vent as cl...

Page 9: ...urn on gas supply D AFTER INSTALLATION 1 Operate system through two complete cycles to check for opening and closing in proper sequence and proper burn er operation DAMPER MUST BE IN OPEN POSITION WHEN BOILER MAIN BURNERS ARE OPERATING 2 Perform installation checks as required by ANSI specifica tion Z21 66 3 Replace the front cover of the boiler 4 Check the troubleshooting section if problems aris...

Page 10: ...n testing various gas manifold and control assemblies used on the Galaxy Series boilers under the ANSI Z21 13b 1994 FIGURE 11 FIGURE 12 Valve VR8200 and VR8300 INSTRUCTIONS Follow the lighting instructions that apply to the particular igni tion system equipped on this boiler Also see figures on page 2 for location of gas manifold gas valve and control assembly 1 Continuous Burning Pilot FOR BOILER...

Page 11: ...the floor because some gas is heavier than air and will settle on the floor 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 s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire depart ment C Use only your hand to push ...

Page 12: ...y movement will cause bright orange flames Wait for dust to settle 3 For one burner close the air shutter until some of its flame jet tips turn yellow white indicating insufficient pri mary air Then open shutter until whitish tips disappear completely Set all burner shutters to the same opening Observe to make sure that no yellow white tips appear over any portion of the flame Small yellow tips at...

Page 13: ...low down your McDonnell cut off more frequently the first week First week 3 times Thereafter at least once a week 2 As boiler water circulates through the float chamber dirt or other sediment may be deposited This chamber is extra deep But the only sure way to keep any accumula tion from interfering with float action is to blow down or flush out the control once a week Do it while boiler is in ope...

Page 14: ...imming FIGURE A Right side view of Galaxy models that are NOT equipped with or DO NOT have provisions for tankless heaters FIGURE B Left side view of Galaxy models that are equipped with or have provisions for tankless heaters only Fire boiler to produce steam If the system is heavily laden with oil it may be difficult to obtain much more than a pound or so of pressure Set the pressure control at ...

Page 15: ...air as required Air needs are greatest in cold weather Air vents must be open and free of obstruction F WATER SYSTEM check 1 System to be full of water and pressure to remain sta ble at correct setting on gauge 2 Air control system noise and air binding in radiation should not occur 3 Water lines slightest leaks should be corrected 4 Low water cut off for operation see instructions fur nished with...

Page 16: ...nst freeze up in the event of power failure or control shutdown when the building is unoccu pied It should be recognized that unless the building is kept above freezing temperature by some means the plumbing system is not protected Two types of anti freeze may be used ETHYLENE GLY COL used in automobiles has desirable properties but is toxic Its use may be prohibited when system water glycol solut...

Page 17: ...H LIMIT CONTACTS CLOSED LOW WATER CUT OFF WHEN USED CONTACTS CLOSED PRESSURE CUT OUT WHEN USED CONTACTS CLOSED VENT DAMPER RELAY ENERGIZED VENT DAMPER MOTOR MOVES OPEN VENT DAMPER END SWITCH CLOSES IGNITION CONTROL ENERGIZED SPARK GENERATOR MODULE POWERED S8600F OR S8600M IGNITION SPARK STARTS AND PILOT VALVE OPERATOR OPENS S8670E IGNITION SPARK AND PILOT VALVE OPERATOR DELAYED FOR 30 70 SECONDS L...

Page 18: ...RS WITH INPUT UNDER 300 000 BTU HR MODELS WITH CONTINUOUS PILOT AND VENT DAMPER CAUTION Label all wires prior to disconnection when servicing control Wiring errors can cause improper and dangerous operation Verify proper operation after servicing ...

Page 19: ...WITH INPUT OF 300 000 BTU HR MODELS WITH CONTINUOUS PILOT AND OPTIONAL VENT DAMPER CAUTION Label all wires prior to disconnection when servicing control Wiring errors can cause improper and dangerous operation Verify proper operation after servicing ...

Page 20: ...B N H 1 EMERGENCY SWITCH HOT BLK P2 2 1 2 A STEAM PZ BOILER WITH CONTINUOUS PLOT VENT DAMPER AND ELECTRONIC L W C O RECEPTACLE B N H BLOCKED VENT SAFETY SWITCH MUST BE MOUNTED TO DRAFT HOOD BEFORE OPERATING THE BOILER SEE INSTRUCTION MANUAL GG 40 BEFORE INSTALLING VENT DAMPER READ WARNING LABEL ON THIS BOILER AND VENT DAMPER READ SLANT FIN VENT DAMPER INSTALLATION INSTRUCTIONS 2 1 4 GALAXY BLK YEL...

Page 21: ...EL SAFGARD CONTACTS SHOWN WHEN BOILER WATER IS AT NORMAL LEVEL THERMOSTAT PRESSURE CUT OUT L2 NEUTRAL WHITE BLUE ROLL OUT SWITCH VIOLET YELLOW RED BLUE MALE PLUG WHITE RED PLUG SCREW TERMINALS PROBE WHITE NEUTRAL EMERGENCY SWITCH ELECTRONIC L W C O N H L1 L W C O P2 2 1 3 2 1 H N W B N H 1 EMERGENCY SWITCH HOT BLK P2 2 1 2 A ALARM OR WATER FEEDER IF USED 1 3 2 RECEPTACLE B N H BLOCKED VENT SAFETY ...

Page 22: ... PILOT VALVE COIL MV PV MV PV L1 L2 24V GND SPARK BLACK 4 MM 67 L W C 0 EMERGENCY SWITCH H N HOT BLK 1 4 3 2 1 ROLL OUT AND BLOCKED VENT SAFETY SWITCHES ROLL OUT AND PILOT GAS 2 1 4 BEFORE INSTALLING VENT DAMPER READ WARNING LABEL ON THIS BOILER AND VENT DAMPER READ SLANT FIN VENT DAMPER INSTALLATION INSTRUCTIONS GND BLK YEL BLACK WHT YEL WHITE IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPL...

Page 23: ...ED FIELD SUPPLIED RECEPTACLE B CONNECTS TO MALE PLUG ON ADAPTER HARNESS VENT DAMPER HARNESS SUPPLIED WITH VENT DAMPER 3 1 2 3 4 WIRE NUT BLUE PRESSURE CUT OUT MALE PLUG 41 1135F S8600 OR S8670 PILOT LIGHTER THERMOSTAT WATER FEEDER OR ALARM IF USED PLUG ELECTRONIC L W C O L2 ELECTRIC IGNITION PILOT THERMOSTAT VIOLET BLACK RED WHITE PILOT GAS 250 C IGNITION CABLE GND BURNER MV PV P ALARM OR WATER FE...

Page 24: ...M OR S8670E ONLY FOR NATURAL GAS S8600F S8600M OR S8670E BLOCKED VENT SAFETY SWITCH MUST BE MOUNTED TO DRAFT HOOD BEFORE OPERATING THE BOILER SEE INSTRUCTION MANUAL GG 40 2 1 4 GALAXY VENT DAMPER HARNESS SUPPLIED WITH VENT DAMPER RECEPTACLE A BLK YEL WHT YEL BLACK WHITE BOILERS WITH INPUT OF 300 000 BTU HR OR GREATER BEFORE INSTALLING OPTIONAL VENT DAMPER READ WARNING LABEL ON THIS BOILER AND VENT...

Page 25: ...DUIT RECEPTACLE B CONNECTS TO MALE PLUG ON ADAPTER HARNESS 1 2 3 4 3 1 2 3 4 3 1 2 EMERGENCY SWITCH MV PV MV PV GND IGNITION CABLE 250 C RED WHITE GREEN GND GND BURNER MV PV MV PV 1 HOT BLK HIGH LIMIT THERMOSTAT OR CORONTROLER 24V THERMOSTAT OR CONTROLER HOT WATER S BOILER WITH 24V HONEYWELL INTERMITTENT IGNITION OPTIONAL VENT DAMPER AND HI LIMIT CONTROL CONSTANT CIRCULATION HIGH LIMIT IF THE WIRE...

Page 26: ...26 GALAXY PUMP OR VALVE ZONING OF WATER BOILERS COMBINATION CONTROLS WITH T TV Z TERMINALS ...

Page 27: ...e chimney or venting system REMEDY 1 Check clean re light See instructions 2 Open gas valve s 3 Close switch 4 Replace fuse 5 Check control Clean contacts or replace control 6 Repair or replace 7 Replace aquastat 8 Check clean and reinstall 9 Check with test light and correct 10 Check and correct in accordance with wiring diagrams included with appliance instructions 11 Install proper controls 12 ...

Page 28: ...sonnel Only simple easily identified controls and parts may be obtained locally All other controls and parts should be identified by and ordered from Slant Fin Relief Safety valves must be ASME rated for the pressure and gross output of the boiler The air control system and pressure control system must oper ate with chiller only or the boiler only being valved to the piping system Separate control...

Page 29: ...s such as range hoods and bathroom exhausts so they will operate at maxi mum speed DO NOT operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously e Test for spillage at the draft hood relief opening after 5 min utes of main burner operation Use the flame of a ma...

Page 30: ...SLANT FIN CORPORATION Greenvale N Y 11548 Phone 516 484 2600 FAX 516 484 5921 Canada Slant Fin LTD LTEE Mississauga Ontario www slantfin com Slant Fin Corp 2006 ...

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