Operating instructions

ManualsBrandsCal Flame ManualsHeating SystemFPT-1100

CONTENTS ...........................................................................PAGE

Ratings, Dimensions, Data...........................................................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............................................................ 6

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............................. 13

Controls, Safety Check......................................................... 14

Low Water Cut-off Check-Out ................................................... 14

Pressure Control Check-Out ..................................................... 14

Blowing Off a Steam Boiler........................ ............................... 15

Care and Maintenance.............................................................. 16

Safety Check for Control System......................................... 17

Protection From Freezing..................................................... 17

Water Treatment..................................... .............................. 17

Sequence of Operations............................... ...................... 18, 19

Pump or Valve Zoning—Water Boilers.............. ....................... 20

Troubleshooting Guide...............................................................21

Appendix A ................................................................................ 22

Appendix B & C......................................................................... 23

Appendix D & E ..........................................................................24

Printed in Canada 01/07 PUBLICATION GG-40

Part No. 41-0549 Rev. K

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

GALAXY

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

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 4 of this instruction book.

The above warning does not apply to NATURAL gas-

fired boilers.

The installation must conform to the requirements of the

authority having jurisdiction or, in the absence of such

requirements, to the National Fuel Gas Code, ANSI Z223.1-

latest edition or

CSA B149.1-00 for natural gas and

propane

. The installation must also conform to the

additional requirements in this Slant/Fin Instruction Book.

In addition, where required by the authority having jurisdic-

tion, the installation must conform to American Society of

Mechanical Engineers Safety Code for Controls and Safety

Devices for Automatically Fired Boilers, No. CSD-1 or

CSA

B149.1-00 for natural gas and propane

. If there is any

conflict in the above requirements, then the more stringent

requirement will apply.

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,

connected, 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.

Heating Contractor

Address

Phone Number

Boiler Model Number

Boiler Serial Number

Installation Date

Summary of content (24 pages)

PAGE 1
GAS-FIRED CAST IRON BOILERS FOR NATURAL AND L.P. PROPANE GASES GALAXY 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 INSTALLATION AND OPERATING INSTRUCTIONS CONTENTS ...........................................................................PAGE Ratings, Dimensions, Data...........................................................2 Installation Requirements: Boiler Location...............................................
PAGE 2
GALAXY Pressure Relief Valve 19 mm (3/4") 13 mm (1/2') Vent Tapping Alternate 38 mm (1-1/2") return (except GG-75 thru GG-175 FRONT VIEW All GG and GXH RIGHT SIDE GG / GXH-PT RIGHT SIDE GXH-PZT-PPZT RIGHT SIDE GXH-PZ GG SERIES HOT WATER BOILERS—DIMENSIONS IN MM FOLLOWED BY INCHES A B C D E F G H J K GG-75H 502 193/46 335 133/16 127 566/6 1178 463/86 171 63/46 203 866/6 32 11/46 38 11/26 70 23/46 235 91/46 GG-100H 502 193/46 335 133/16 152 666/6 1353 531/46 330 131/46 203 866/6 32 11/46 38 11/26 7
PAGE 3
GALAXY INSTALLATION REQUIREMENTS The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1-latest edition or CSA B149.1-00 for natural gas and propane. This installation must also conform to the additional requirements in this Slant/Fin instruction book. Installation and service to be performed by a qualified installer, service agency or the gas supplier.
PAGE 4
GALAXY GALAXY GXH SERIES MODELS GXH-105 THROUGH GXH-190 MINIMUM CLEARANCE FOR COMBUSTIBLE CONSTRUCTION. MINIMUM CLOSET CLEARANCE. Front 152 mm (6") Rear 152 mm (6") Left Side 152 mm (6") Right Side 457 mm (18") Top 914 mm (36")* Flue Connector 152 mm (6") Type 'B' Vent 25 mm (1") MODELS GXH-210 TO GXH-300H, GX-225 TO GX-250. MINIMUM CLEARANCE FOR COMBUSTIBLE CONSTRUCTION. MINIMUM ALCOVE CLEARANCE.
PAGE 5
GALAXY 5 than maximum pressure when the boiler or any other appliance is turned on or off. ELECTRICAL CONTROLS AND WIRING A. The electrical power to the boiler must be on a separately fused and live circuit. B. If an external electrical source is utilized, the boiler, when installed, must be electrically grounded in accordance with the requirements of the authority having jurisdiction or, in absence of such requirements, with the Canadian Electric Code – CSA-C22.1, Part 1 – latest edition. C.
PAGE 6
DRAFT HOOD— The draft hood supplied is part of the listed boiler assembly. DO NOT alter the hood. See dimensions, page 2. Attach the hood to the boiler flue outlet. Connect flue pipe full size of hood outlet. If a vent damper is added, it must be installed on the outlet side of the hood. See Vent Piping, on page 5, 8, 9. (Figures 4, 5, 8.) PIPING AT BOILER — WATER PIPING A. CIRCULATING SYSTEMS 1.
PAGE 7
GALAXY 7 cases has an air vent on the receiver. A gravity return system has no receiver, so provisions for air removal must be made on the piping itself. A one pipe system has the air vents on the radiation, the heat exchanger and near the end of the steam supply main (see figures 2 and 3). Main air vents should be located fifteen inches from the drop and if possible eight inches above the pipe so that water hammer does not damage the vent and render the vent inoperable.
PAGE 8
GALAXY VENT DAMPER INSTALLATION The vent damper referred to in the following instructions is the Slant/Fin LTD/LTEE vent damper. A. This device is design certified by C.G.A. for use ONLY on specific Slant/Fin gas boiler models. These boilers must also be equipped with a plate which states that the boiler must or may be used with a Slant/Fin automatic vent damper device and indicates the proper vent damper model number. This device cannot be used with a millivolt ignition system. B.
PAGE 9
GALAXY 9 FIGURE 8 FIGURE 9 CAUTION DO NOT USE ONE VENT DAMPER TO CONTROL TWO HEATING APPLIANCES DAMPER DANGEROUS HEATING APPLIANCE HEATING APPLIANCE WRONG WAY DAMPER HEATING APPLIANCE HEATING APPLIANCE CORRECT WAY 3. Boilers that have a vent damper are factory wired with a male plug.
PAGE 10
GALAXY CLEAN STEAM BOILER SYSTEM A. Fill the boiler to water line indicated on the boiler. B. Follow start-up procedure for boiler and operate the boiler with steam in the entire system for 2 or 3 days to bring oil and dirt from the system to the boiler. While system is in operation, maintain the proper water level in the boiler by slowly adding water to the boiler. C. Shut down burner, cool down boiler and drain system. D. Procedure to dissolve oil and grease in boiler: 1.
PAGE 11
GALAXY 2. Continuous Burning Pilot (24V). FOR BOILERS EQUIPPED WITH HONEYWELL GAS VALVE VR8200, VR8300, V8200 or V800. (see figures 10 and 11). SAFETY INFORMATION FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly. B.
PAGE 12
GALAXY Operating Instructions 1. 2. 3. 4. STOP! Read the safety information above on this page. Set the thermostat to lowest setting. Turn off all electric power to the appliance. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. 5. Remove control access panel. GAS VALVE 36C84 GAS INLET OF F ON Gas Control Knob Shown in Off Position 6.
PAGE 13
GALAXY 13 i. Boiler (burner) is overfiring. CAUTION! National Fuel Gas Code ANSI Z223.1-latest edition or CSA B149.100 for natural gas and propane, does NOT permit firing at a higher input rate than the input rate indicated on the boiler rating plate in order to avoid hazardous conditions such as explosion or carbon monoxide poisoning. ii. Poor higher heating value* of gas is causing the actual input to be substantially lower than the rating plate indication.
PAGE 14
GALAXY C.Main Burner Ignition Check-out and Pilot Adjustment 1. The pilot flame must not smother or snuff out when tested as follows: i. Main burner ignition from cold start-repeat. ii. Continued operation of main burner. iii.Main burner ignition with appliance at maximum operating temperature after prolonged operation. NOTE: Observe operation of the pilot burner with appliance doors in the final operating position. Use of a mirror may be helpful. 2. Safety Shutdown Check-out i.
PAGE 15
GALAXY 15 5. Fittings 6. Instruction sheet and assembly drawing. 7. Steam safety valve and 19 mm (3/4") street coupling. 8. Drain cock. Assembly above components exactly as shown. Two 13 mm (1/2") tappings are on right side of boiler for this assembly. Two holes are pre-punched in jackets. Replacement of Steam Boilers A. Anytime an older steam boiler is removed from the heating system and replaced with a new boiler, there are certain conditions that have to be examined in the heating system. 1.
PAGE 16
GALAXY pop safety valve and re-pipe boiler as shown in Figure B below, making sure to reinstall pop safety valve on tee to complete the blow off connection. 2. Connect a length of pipe to the elbow and place a bucket underneath the open end of the pipe, cover bucket with a piece of cloth. 3. Open the SKIMMER drain valve with caution. DO NOT open the boiler drain valve. Fill the boiler slowly until water begins to seep into the bucket from the skimmer drain blow-off connection. Fire the boiler.
PAGE 17
GALAXY d. Clean and replace burners* and pilot. Adjust burners as described on page 13. * To clean burners run a clean flue brush up the tube until all foreign matter is removed. SAFETY CHECK FOR CONTROL SYSTEM A. High limit control test: Set thermostat high enough for boiler water temperature to reach high limit control setting. When this temperature is reached, the high limit switch should open, and the main gas valve should close automatically.
PAGE 18
GALAXY 18 SEQUENCE OF OPERATION FOR GALAXY BOILERS EQUIPPED WITH CONTINUOUS BURNING PILOT (HONEYWELL OR WHITE RODGERS) LIGHTED PILOT HEATS THERMOCOUPLE AND KEEPS PILOTSTAT OPEN. THERMOSTAT CALLS FOR HEAT LOW LIMIT (FOR TANKLESS COIL) CALLS FOR HOT WATER OR HIGH-LIMIT CONTACTS CLOSED? LOW WATER CUT-OFF (WHEN USED) CONTACTS CLOSED? PRESSURE CUT-OUT (WHEN USED) CONTACTS CLOSED? NO NO FURTHER ACTION YES VENT DAMPER RELAY ENERGIZED. VENT DAMPER MOTOR MOVES OPEN (VENT DAMPER OPENS). END SWITCH CLOSES.
PAGE 19
GALAXY 19 SEQUENCE OF OPERATION FOR SLANT/FIN BOILERS EQUIPPED WITH WHITE RODGERS INTERMITTENT IGNITION SYSTEM THERMOSTAT CALLS FOR HEAT OR LOW LIMIT (FOR TANKLESS COIL) CALLS FOR HOT WATER Ð RELAY ENERGIZES Ð Î CIRCULATOR ENERGIZED WHEN USED WITH COMBINATION AQUASTAT CONTROL ON HOT WATER BOILERS ONLY VENT DAMPER MOTOR ENERGIZED VENT DAMPER IF INCLUDED Ð VENT DAMPER OPEN Ð SEND SWITCH CLOSES Ð HIGH LIMIT OR PRESSURE CUT-OUT CLOSED (NORMAL OPERATING POSITION) Ð LOW WATER CUT-OFF (WHEN USED) C
PAGE 20
GALAXY 20 PUMP OR VALVE ZONING OF WATER BOILERS COMBINATION CONTROLS WITH T TV Z TERMINALS* L8148L8124 TO ADDITIONAL R845A RELAYS FOR OTHER ZONES R845A RELAYS ZONE 1 V8043F V8043F V8043F ADD JUMPER AS SHOWN LOW VOLTAGE GAS VALVE L8148L8124 LOW VOLTAGE THERMOSTAT HOT POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. USE TYPE 105°C WIRE OR EQUIVALENT TO BURNER CIRCUIT CIRCULATOR POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
PAGE 21
GALAXY BURNERS FAIL TO OPERATE CAUSE 1. Safety pilot out, or flame too low. 2. Gas supply valve shut off. 3. Electric switch open. 4. Blown or defective line fuse. 5. Operating or limit control contacts open or dirty. 6. Defective gas valve or pressure regulator; or plugged bleed line. 7. Defective low voltage transformer. 8. Obstruction at main burner orifice. 9. Break in wiring or loose contact at control terminals. 10. Improper wiring. 11. Improper controls. 12.
PAGE 22
GALAXY APPENDIX A Removal of Existing Boiler from Common Vent System "At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation." (a) Seal any unused openings in the common venting system.
PAGE 23
GALAXY 23 APPENDIX B Thermostatic Bypass Valve Thermostatic bypass valves type TV are designed to allow boilers to reach their optimum operating temperature quickly and to prevent cool/cold return temperatures from affecting them. established. If flow is already to the system, no adjustment is required. Return Mounting: On the return "TV" allows full bypass until the return temperature reaches 46 degrees Celsius (115 degrees Fahrenheit).
PAGE 24
GALAXY APPENDIX D Accumulation of Foreign Deposits in Heat Exchanger Investigations of boilers which were installed in hard water areas, revealed that mineral deposits had accumulated at the bottom of the heat exchanger. In addition, sludge, scale and other solid contaminants were present in boilers installed in older systems or where the water was supplied from a well.