GSA
Gas-Fired Steam Boilers –
Boiler Manual
7
Part Number 550-110-738/1012
1 Prepare boiler location
continued
Setup -
continued
Inspect orifices and burners
1. Remove front jacket door. Remove base access panel (see
Figure 20, item 14, page 26).
2. Check for correctly‑sized manifold orifices. See Table 3
for sizing. (The orifice size is stamped on the orifice spud
barrel.)
Correctly‑sized manifold orifices must be used.
Failure to do so will result in severe personal injury,
death or substantial property damage.
3. Level and straighten burners.
Burners must be properly seated in slots in burner
rest with their openings face up. Main burner orifices
must inject down center of burner. Failure to properly
seat burners will result in severe personal injury,
death or substantial property damage.
4. Reinstall base access panel.
Do not operate boiler without access panel secured
in place. Failure to comply could cause momentary
flame rollout on ignition of main flame, resulting in
possible fire or personal injury hazard.
Table 3
Manifold orifice sizing
Pressure test
Perform hydrostatic pressure test
Pressure test boiler before attaching water or gas piping or
electrical supply.
Prepare boiler for test
1. Plug tappings or openings.
2. Do not use gauge supplied with boiler for pressure testing.
Install gauge with appropriate range.
Fill and pressure test
1. Fill boiler with water. Vent all air. Test boilers between 45‑
50 psi.
Do not leave boiler unattended. A cold water fill 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 repairing leaks.
3. Remove plugs from any tappings that will be used for controls
and accessories. Refer to Table 4 and Figure 3.
Float‑type low water cutoff — If field installing a
float‑type low water cutoff, it must be piped only to
the gauge glass tappings, items H, Figure 3. The
tappings are spaced 9” on center. Use only float‑type
low water cutoffs with quick‑connect hookups that
will provide a low water cutoff point no higher than
2” above the center of the bottom tapping. See page
14, Figure 16, for a typical installation.
Pressure test -
continued
Table 4
Control tapping
Figure 3
Control tapping locations
Drain and remove fittings
1. Drain boiler and repair leaks if found.
Leaks must be repaired at once. Failure to do so
can damage boiler, resulting in substantial property
damage.
Location
Natural gas
U.S.
Sea level – 2,000 ft.
2.45 mm
over 2,000 ft.
(Note 1)
Canada
Sea level – 2,000 ft.
2.45 mm
2,000 ft. - 4,500 ft.
2.30 mm
Note 1: For U.S. elevations above 2,000 feet, contact your local
supplier for details.
Location
Size
Description
C
¾”
Probe-typelow water cutoff
D
¾”
Drain
E
¾”
Relief valve
G
¾”
Plugged
H
½”
Gauge glass and/or optional
low water cutoff
J
(See Note)
⅜”
Tricock tappings
L
½”
Siphon, pressure gauge, high
limit control
S
1 ½”
Skim tapping
Note: Available only on special request.