Table of Contents
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Hazards that will cause severe personal injury,
death or substantial property damage.
Hazards that can cause severe personal injury,
death or substantial property damage.
INSTALLER - Read all instructions before
installing. 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 transportation
company by the consignee.
• GSA boilers cannot be adapted for heater use.
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 16.
G SA
Gas-Fired Steam Boilers
Boiler Manual
Contents
1 Prepare boiler location ........................................................ 2
2 Prepare boiler ..................................................................... 6
3 Install piping ........................................................................ 9
4 Install controls .................................................................. 11
5 Install gas piping ............................................................... 12
6 Field wiring ....................................................................... 13
7 Start-up ............................................................................ 14
8 Checkout procedure ......................................................... 16
9 Sequence of operation ...................................................... 17
10 Lighting instructions .......................................................... 18
11 Service and maintenance ................................................. 20
12 Troubleshooting ................................................................ 24
13 Replacement parts ........................................................... 26
14 Dimensions ...................................................................... 30
15 Ratings ............................................................................. 31
Hazard definitions
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.
• This manual is for use only by your qualified
• Please see the User's Information Manual for your
• Have the boiler serviced by a qualified service
USER - Please read the following. Failure to
comply could result in severe personal injury, death
or substantial property damage.
heating installer/service technician.
reference.
technician, at least annually.
Part Number 550-110-738/0703
Page
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Table of Contents
Summary of Contents for Calumet GSA
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Page 1: Table Of Contents
• Have the boiler serviced by a qualified service • GSA boilers cannot be adapted for heater use. technician, at least annually. 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. -
Page 2: Prepare Boiler Location
2. To avoid severe burns, allow boiler to cool before performing maintenance. Certification The GSA boiler gas manifold and controls met safe Boiler operation — lighting and other performance criteria when boiler 3. Do not block flow of combustion or ventilation air to boiler. -
Page 3: Residential Garage Installation
Small space — alcove (not closet) installation • Locate or protect the boiler so it cannot be damaged by a moving GSA boilers are not approved for closet installation vehicle. — only for alcove installation, with minimum clearances as shown in Figure 1 and the table below, Flooring and foundation and the front side completely open —... -
Page 4: Vent System
GSA Gas-Fired Steam Boilers – Boiler Manual 1 Prepare boiler location continued Vent system Failure to follow all instructions can result in flue gas Equipment”, of National Fuel Gas Code, ANSI Z223.1–latest spillage and carbon monoxide emissions, causing edition and applicable building codes. Canadian installations severe personal injury or death. -
Page 5: Air Openings
GSA Gas-Fired Steam Boilers – Boiler Manual 1 Prepare boiler location continued Air contamination Air openings Please review the following information on potential combustion air Combustion air and ventilation openings must comply with Section contamination problems. 5.3, “Air for Combustion and Ventilation”, of National Fuel Gas Code ANSI Z223.1–latest edition, or applicable local building codes. -
Page 6: Prepare Boiler
GSA Gas-Fired Steam Boilers – Boiler Manual 1 Prepare boiler location continued Air openings continued Exhaust fans and air movers Motorized air dampers The appliance space must never be under a negative pressure. If the air openings are fitted with motorized dampers, electrically... - Page 7 GSA Gas-Fired Steam Boilers – Boiler Manual 2 Prepare boiler continued Pressure test Draft diverter & spill switch continued Drain and remove fittings Draft diverter installation 1. Drain boiler and repair leaks if found. 1. Secure draft diverter to flue collector hood with sheet metal Leaks must be repaired at once.
- Page 8 GSA Gas-Fired Steam Boilers – Boiler Manual 2 Prepare boiler continued Vent damper These systems are used on gas-fired boilers with vent dampers as shipped from factory. Boiler will not operate without vent damper installed. Damper blade See vent manufacturer’s instructions to install plug (shipped with damper) in damper hole.
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Page 9: Install Piping
GSA Gas-Fired Steam Boilers – Boiler Manual 3 Install piping General Connecting to counterflow piping 1. Pipe before installing controls. Connect return piping after jacket Apply the recommended piping in Figures 4 through 7 only when is attached. Connect supply piping before or after jacket is connecting to a parallel-flow system. - Page 10 GSA Gas-Fired Steam Boilers – Boiler Manual 3 Install piping continued Relief valve Condensate return continued During operation, this valve may discharge large Modern steam boilers are designed to steam for less time than amounts of steam and/or hot water. Therefore, to older, larger boilers.
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Page 11: Install Controls
GSA Gas-Fired Steam Boilers – Boiler Manual 4 Install controls Controls Float-type low water cutoff (when provided by others) Failure to properly install, pipe and wire boiler controls may result in severe damage to the boiler, building 1. Install low water cutoff as shown in Figure 9, below. See Table 4 and personnel. -
Page 12: Install Gas Piping
GSA Gas-Fired Steam Boilers – Boiler Manual 5 Install gas piping Connecting gas supply piping to boiler Natural Gas: 1. Remove jacket front panel and see Figure 10 to pipe gas to boiler. 1. See Table 8 for pipe length and diameter. Base on rated boiler a. -
Page 13: Field Wiring
GSA Gas-Fired Steam Boilers – Boiler Manual 6 Field wiring For your safety, turn off electrical power supply at Wiring connections service entrance panel before making any electrical connections to avoid possible electric shock hazard. Boiler is shipped with controls completely wired, except spill switch Failure to do so can cause severe personal injury or and vent damper. -
Page 14: Start-Up
GSA Gas-Fired Steam Boilers – Boiler Manual 7 Start-up Skimming the boiler Preparation Clean all newly installed steam boilers to remove oil and grease. Failure to properly clean can result Check for gas leaks in violent fluctuations of water level, water passing... - Page 15 GSA Gas-Fired Steam Boilers – Boiler Manual 7 Start-up continued 2. Underfired — Small flame. Inner cone not engulfing Operate boiler continued thermocouple. 3. Lack of primary air — Yellow flame tip. Start the boiler 4. Incorrectly heated thermocouple. 1. Check boiler water level — Should be approximately ½ way up gauge glass.
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Page 16: Checkout Procedure
GSA Gas-Fired Steam Boilers – Boiler Manual 8 Checkout procedure ❏ ❏ Boiler filled with water? Test ignition system safety device — Turn gas cock knob to PILOT position and extinguish pilot flame. Pilot gas flow should ❏ Boilers properly skimmed? stop in less than 3 minutes. -
Page 17: Sequence Of Operation
GSA Gas-Fired Steam Boilers – Boiler Manual Part Number 550-110-738/0703... -
Page 18: Lighting Instructions
GSA Gas-Fired Steam Boilers – Boiler Manual 10 Lighting Instructions — GSA standing pilot boilers Honeywell VR8200/VR8300 gas valve FOR YOUR SAFETY READ BEFORE LIGHTING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. - Page 19 GSA Gas-Fired Steam Boilers – Boiler Manual 10 Lighting Instructions — GSA-30 through GSA-50 Robertshaw 7200 gas valve FOR YOUR SAFETY READ BEFORE LIGHTING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
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Page 20: Service And Maintenance
GSA Gas-Fired Steam Boilers – Boiler Manual 11 Service and maintenance Table 9 Service and maintenance schedules (service technician and owner) Service technician Owner maintenance (see following pages for instructions) (see User’s Information Manual for instructions) ❏ Inspect: ❏ Daily •... - Page 21 GSA Gas-Fired Steam Boilers – Boiler Manual 11 Service and maintenance continued The boiler should be inspected and started annually, ❏ ❏ ❏ ❏ ❏ Inspect ..at the beginning of the heating season, only by a qualified service technician.
- Page 22 GSA Gas-Fired Steam Boilers – Boiler Manual 11 Service and maintenance continued ❏ ❏ ❏ ❏ ❏ Service..❏ ❏ ❏ ❏ ❏ Check/test..
- Page 23 GSA Gas-Fired Steam Boilers – Boiler Manual 11 Service and maintenance continued ❏ ❏ ❏ ❏ ❏ Check/test..❏ ❏ ❏ ❏ ❏ Review with owner 1. Review the User’s Information Manual with the owner.
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Page 24: Troubleshooting
GSA Gas-Fired Steam Boilers – Boiler Manual 12 Troubleshooting In event of vent damper failure: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and Effikal vent damper dangerous operation. Never jumper (bypass) rollout thermal fuse element... - Page 25 GSA Gas-Fired Steam Boilers – Boiler Manual 12 Troubleshooting continued Chart 1 — Standing pilot — Boiler will not fire Before proceeding, follow "Troubleshooting sequence" on page 24. If problem persists, then: Is damper harness securely plugged in at both ends? Secure connections.
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Page 26: Replacement Parts
GSA Gas-Fired Steam Boilers – Boiler Manual 13 Replacement parts Figure 16 Section assembly, flue collector, draft diverter, vent damper and base assembly The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 32 of this manual. - Page 27 GSA Gas-Fired Steam Boilers – Boiler Manual 13 Replacement parts continued Figure 17 Jacket assembly The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 32 of this manual. Failure to comply could result in severe personal injury.
- Page 28 GSA Gas-Fired Steam Boilers – Boiler Manual 13 Replacement parts continued Figure 18 Controls and trim Part Number 550-110-738/0703...
- Page 29 GSA Gas-Fired Steam Boilers – Boiler Manual 13 Replacement parts continued Figure 19 Gas controls Part Number 550-110-738/0703...
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Page 30: Dimensions
GSA Gas-Fired Steam Boilers – Boiler Manual 14 Dimensions Figure 20 Dimensional drawing — ALL DIMENSIONS IN INCHES Boiler Supply Return Gas connection “V” “D” “W” Approximate model tapping tapping & manifold size Damper Vent Jacket shipping number height diameter... -
Page 31: Ratings
GSA Gas-Fired Steam Boilers – Boiler Manual 15 Ratings Notes 1. Based on standard test procedures prescribed by the United States Department of Energy. 2. Net I=B=R ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup. -
Page 32: Handling Ceramic Fiber And Fiberglass Materials
GSA Gas-Fired Steam Boilers – Boiler Manual Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or base insulation panels in this product contain ceramic fiber materials. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, "Crystalline silica inhaled in the form of quartz or cristobalite from occupational...