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Part Number 550-110-738/1012

G SA

Gas-Fired Steam Boilers

Boiler Manual

  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 20.

Contents 

Page

   1  Prepare boiler location .......................................................2
   2  Prepare boiler .....................................................................8
   3  Install piping .....................................................................11
   4  Install controls ..................................................................14
   5  Install gas piping ...............................................................15
   6  Field Wiring ......................................................................16
   7  Start-up ............................................................................17
   8  Checkout procedure .........................................................20
   9  Service and maintenance .................................................21
  10 Replacement parts ...........................................................26
 11  Dimensions .......................................................................30
 12  Ratings .............................................................................31

For Operating and Troubleshooting Instructions,  
see Spark Ignition Control Supplement

  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 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.

  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 document 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.

 

INSTALLER 

— 

 

Spark ignition boilers — 

Refer to this manual 

for general installation and maintenance informa-

tion. Refer also to the GSA Spark Ignition Control 

Supplement, part number 550‑141‑971, for operat-

ing instructions, troubleshooting and other additional 

information  for  GSA  boilers  equipped  with  spark 

ignition.

Содержание GSA-075

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

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

Страница 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 ...

Страница 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...

Страница 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...

Страница 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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