Use and Care Manual

ManualsBrandsSlant/Fin ManualsHeating, Ventilation, and Air ConditioningNatural Gas Steam Boiler 160,000 BTU Input 98,000 BTU Output 408 Sq. Ft. of Steam with Intermittent Electronic Ignition

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—Steam Boilers................... ..........................6

Steam Controls Assembly and Installation.............................6

Piping a Steam Boiler.........................................................6,7

Vent Damper.......................................... ..............................8,9

Operating Instructions:

Filling and Venting Steam Systems...................................9-10

Initial Start, Safety and Lighting Instructions...................10-11

Burner Adjustment, Checking Gas Input...... ........................11

Controls, Safety Check .........................................................12

Low Water Cut-off Check-Out....................................................12

Pressure Control Check-Out .....................................................12

Blowing Off a Steam Boiler........................................................13

Care and Maintenance.................................. ............................14

Safety Check for Control System..........................................14

Water Treatment....................................................................14

Sequence of Operations............................................................15

Wiring Diagrams...................................................................16-17

Troubleshooting Guide...............................................................18

Replacement Parts....................................................................19

Appendix A ................................................................................19

IMPORTANT

READ ALL OF THE FOLLOWING WARNINGS AND

STATEMENTS BEFORE READING THE

INSTALLATION INSTRUCTIONS

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. 1114 PUBLICATION GGS-41

Part No. 41-0881

INSTALLATION AND OPERATING INSTRUCTIONS

LOW PRESSURE STEAM—Models GXH-230 through GXH-300H

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

GALAXY

GAS-FIRED CAST IRON BOILERS FOR

NATURAL AND L.P. PROPANE GASES

STEAM BOILERS

™

Heating Contractor

Address

Phone Number

Boiler Model Number

Boiler Serial Number

Installation Date

WARNING

SEE “WARNING” ON PAGE 3 FOR LIQUEFIED

PETROLEUM (L.P.) PROPANE GAS-FIRED BOILERS

Summary of content (20 pages)

PAGE 1
GALAXY ™ GAS-FIRED CAST IRON BOILERS FOR NATURAL AND L.P. PROPANE GASES STEAM BOILERS INSTALLATION AND OPERATING INSTRUCTIONS LOW PRESSURE STEAM—Models GXH-230 through GXH-300H LOW PRESSURE STEAM—Models GXHA-100 through GXHA-200 CONTENTS .........................................................................PAGE Dimensions............................ ......................................................2 Installation Requirements: Boiler Location........................................ ..............
PAGE 2
GALAXY STEAM BOILER BOILER DIMENSIONS RIGHT SIDE GXH-PZT-PPZT RIGHT SIDE GXH-PZ GXHA Series GXH AND GXHA SERIES STEAM BOILERS - DIMENSIONS IN INCHES A B C D E F G H J K M GXHA-100 GXHA-120 GXHA-160 GXHA-200 GXH-230 GXH-250 GXH-275 GXH-300H 321⁄2 321⁄2 321⁄2 – – – – 293⁄4 161⁄2 161⁄2 20 231⁄4 231⁄4 26 26 26 5 6 6 7 7 7 7 9 551⁄2 551⁄2 591⁄8 – – – – 551⁄2 – – – – 14 14 14 15 131⁄2 13 143⁄4 143⁄4 143⁄4 10 10 113⁄4 – – – – 11⁄2 11⁄2 11⁄2 11⁄2 – – – – 21⁄2 21⁄2 21⁄2 21⁄2 – – – – 31⁄2 31⁄2 31⁄2 31⁄2 – –
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GALAXY STEAM BOILER 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. 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 STEAM BOILER GXH SERIES GXHA SERIES MODELS GXH-230 TO GXH-300H, MINIMUM CLEARANCE FOR COMBUSTIBLE CONSTRUCTION. MINIMUM ALCOVE CLEARANCE. Front Alcove Rear 6" Left Side 6" Right Side 18" Top 36" Flue Connector 6" Type 'B' Vent 1" MODELS GXHA-100, GXHA-120, GXHA-160 & GXHA-200 MINIMUM CLEARANCE FOR COMBUSTIBLE CONSTRUCTION. CLOSET AND ALCOVE CLEARANCE. Front 6" Rear 6" Left Side 6" Right Side 18" Top 18" Flue Connector 6" Type 'B' Vent 1" B.
PAGE 5
GALAXY STEAM BOILER 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 National Electrical Code, ANSI/NFPA No. 70-latest edition. C. Basic control wiring diagrams are given on pages 16-17.
PAGE 6
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 4. INSTALLATION INSTRUCTIONS FOR GXH OR GXHA LOW PRESSURE STEAM BOILERS EQUIPPED WITH TANKLESS OR PROVISION FOR TANKLESS AND McDONNELL & MILLER TYPE 67 LOW WATER CUT-OFF. STEAM CONTROLS ASSEMBLY AND INSTALLATION INSTRUCTIONS Steam kit components for Galaxy packaged models are packed as follows: A. 1.
PAGE 7
GALAXY STEAM BOILER 5. Process water applications involving steam boilers requires the use of heat exchangers. Any process application that constantly uses fresh water into a steam boiler can and will cause scaling with deposits forming in the boiler and surrounding piping. This will damage the boiler. 6. If valves are used on the supply side of the boiler, the valve port opening must be the same size as the surrounding pipe. (Full flow type valves.) 7.
PAGE 8
GALAXY STEAM BOILER VENT DAMPER INSTALLATION The vent damper referred to in the following instructions is the Slant/Fin Corporation vent damper. This device is design certified by A.G.A. for use ONLY on specific Slant/Fin Corp. 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 Corp. automatic vent damper device and indicates the proper vent damper model number. A. INSTALLATION INSTRUCTIONS BEFORE YOU START TO INSTALL 1.
PAGE 9
GALAXY STEAM BOILER 9 FIGURE 8a & 8b GXHA boilers only: Two provided red wires must be connected to “blocked vent safety switch located on the rear section of the draft diverter (see figure 7). 6. Restore electrical power and turn on gas supply. FIGURE 9 "RECEPTACLE A" from "MALE PLUG". Remove "RECEPTACLE A" from job site and discard. 2. Separate the vent pipe directly on top of the draft hood or diverter and place damper in position as shown in figures 4 - 9.
PAGE 10
GALAXY STEAM BOILER (a)Pour solution into the boiler through a top tapping. Replace plug. 3. Start the burner; boil the water for at least 5 hours; shut off the burner. E.With CAUTION, drain the boiler solution to a safe location. DO NOT LEAVE SOLUTION SITTING IN SYSTEM OVER 2 HOURS. F. Wash the water side of the boiler thoroughly using a high pressure water stream. Fill and drain the boiler several times. III. TREATING WATER FOR CORROSION CONTROL (This is not scale control.) A.
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GALAXY STEAM BOILER BURNER ADJUSTMENT A.Adjust gas input rate: 1. Consult gas supplier for heating value of gas (Btu/cu.ft.). 2. Set thermostat high enough so that boiler will remain on while checking rate. 3. Measure manifold pressure at 1/8" tapping. Correct manifold pressure for gas used is printed on boiler rating plate. NOTE: Gas pressure may be adjusted by turning pressure regulator screw on combination gas valve (Turn clockwise to increase pressure, counterclockwise to decrease pressure). a.
PAGE 12
GALAXY STEAM BOILER CONTROLS, SAFETY CHECK Check all safety controls not previously mentioned. Also, follow directions in "CARE AND MAINTENANCE" section. 12 Steam controls assembly These boilers are equipped with both a draft hood blocked vent safety switch and a rollout safety switch. The blocked vent safety switch is located on the draft hood flue stack. This is a manual reset control used to prevent excessive spillage of flue gases from the draft hood.
PAGE 13
GALAXY STEAM BOILER Replacement of Steam Boilers 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 on the heating system. 1. Steam systems have a tendency to develop scale inside the wet return lines and the boiler. The older the system the greater the accumulation of scale that can exist inside the piping.
PAGE 14
GALAXY STEAM BOILER C. 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. Allow water to heat up while water seeps into the bucket. Maintain that water level necessary just to be able to continue skimming. Continue until water is clean and no oil can be seen floating in the bucket. Empty bucket frequently in order to see if the water is clean. D.
PAGE 15
GALAXY STEAM BOILER 15 SEQUENCE OF OPERATION FOR GALAXY STEAM BOILERS THERMOSTAT CALLS FOR HEAT LOW LIMIT (FOR TANKLESS COIL) CALLS FOR HOT WATER OR NO LOW WATER CUT-OFF CONTACTS CLOSED? PRESSURE CUT-OUT CONTACTS CLOSED? L.P. PROPANE GAS (S8600M AND S8670E) IGNITION TRIAL CONTINUES FOR 90 SECONDS. AFTER TRIAL FOR IGNITION, SYSTEM SHUTS OFF. AFTER 5 MINUTES MODULE RE-INSTATES TRIAL FOR IGNITION.
PAGE 16
GALAXY STEAM BOILER WIRING DIAGRAMS FOR STEAM BOILERS WITH 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.” STEAM (PZ,PZT AND PPZT) BOILER WITH 24V HONEYWELL INTERMITTENT IGNITION, VENT DAMPER AND MM-67 L.W.C.O. ( LO LIMIT IF W/ TANKLESS ) STEAM ( PZ ) BOILER WITH 24V HONEYWELL INTERMITTENT IGNITION, VENT DAMPER AND ELECTRONIC L.W.C.O.
PAGE 17
GALAXY STEAM BOILER 17 WIRING DIAGRAMS FOR GXH-300HEZ STEAM BOILER 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.” STEAM ( PZ ) BOILER WITH 24V HONEYWELL INTERMITTENT IGNITION, OPTIONAL VENT DAMPER AND ELECTRONIC L.W.C.O. STEAM (PZ,PZT AND PPZT) BOILER WITH 24V HONEYWELL INTERMITTENT IGNITION, OPTIONAL VENT DAMPER AND MM-67 L.W.C.O.
PAGE 18
GALAXY STEAM BOILER GENERAL TROUBLESHOOTING GUIDE FOR SERVICEPEOPLE 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.
PAGE 19
GALAXY STEAM BOILER IF REPLACEMENT PARTS ARE NEEDED When parts are needed, refer to boiler model and serial number shown on the boiler name/rating plate. Refer to the following parts lists for part numbers; publication number GXH-11PL for Galaxy GXH Series and GXHA-10PL for GXHA Series boilers. Whenever possible refer to the original order by number and date. Control identification and replacement should not be attempted by unskilled personnel.
PAGE 20
©Slant/Fin Corp. 2014 • PUBLICATION GGS-41 • 1114 • Part No. 41-0881 SLANT/FIN CORPORATION, Greenvale, N.Y. 11548 • Phone: (516) 484-2600 FAX: (516) 484-5921 • Canada: Slant/Fin LTD/LTEE, Mississauga, Ontario www.slantfin.