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1. 13 Low Water Cut off Check Out 13 Pressure Control Check Out 13 Blowing Off a Steam Boiler 14 Care and Maintenance eene 15 Safety Check for Control System 16 Protection From Freezing eee 16 Water Treatments r a 16 Sequence of Operations 17 Wiring Diagraitms e 16 25 Pump or Valve Zoning Water Boilers 26 Troubleshooting GuiIde U esiin aqui 27 Piping a Heating and Cooling System 28 Replacement Parts cicli 28 ApBDORGIX 29 Heating Contractor Address Phone Number Printed in U S A 706 Part No 41 0549 IMPORTANT READ ALL OF THE FOLLOWING WARNINGS AND STATEMENTS BEFORE READING THE INSTALLATION INSTRUCTIONS 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 3 of this instruction book The above warning d
2. MALE PLUG MOTI3A CABLE EMERGENCY 24V SWITCH gp BLOCKED VENT SAFETY SWITCH VIOLET I P 24 THERMOSTAT GND P SPARK ELECTRONIC GND LW CO BURNER screw to TERMINALS 2 A 909 GO CO 2 9 1 PV 250 C IGNITION CABLE AT RECEPTACLE MER ELECTRIC IGNITION BLUE r LARM OR WATER FEEDER PV WIRE NUT S VALVE PRESSURE CUT OUT PILOT GAS MV PV FOR McDONNELL amp MILLER L W C O PS 802 24 AND WATER FEEDER WF 2 U 24 ONLY HOT BLK EMERGENCY SWITCH L1 A ROLL OUT BLOCKED VENT WATERFEEDER SLANTIFIN SWITCH SAFETY SWITCH OR ALARM VENT DAMPER IF USED TERMINALS MARKING SHOWN ARE FOR BOILER HARNESS MALE PLUG WIRE LEGEND 2 A FACTORY WIRED WIRE ENTRANCE FIELD CONNECTED ENDS POLARIZED FACTORY SUPPLIED Os connectors FIELD CONNECTED FIELD SUPPLIED RECEPTACLE PROVIDE DISCONNECT MEANS amp OVERLOAD PROTECTION AS REQUIRED IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 105 C OR ITS EQU
3. CONTACTS SHOWN WHEN BOILER WATER IS AT NORMAL LEVEL WIRE LEGEND 2 4 FACTORY WIRED WIRE ENTRANCE FIELD CONNECTED ENDS POLARIZED FACTORY SUPPLIED Os connectors FIELD CONNECTED FIELD SUPPLIED RECEPTACLE A PROVIDE DISCONNECT MEANS amp OVERLOAD PROTECTION AS REQUIRED IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 105 C OR ITS EQUIVALENT IF THE WIRES MARKED P MUST BE REPLACED THEY MUST BE REPLACED WITH POWER LIMITED FIRE PROTECTIVE CABLE GALAXY 41 1194 E GALAXY 23 WIRING DIAGRAMS FOR STEAM BOILERS WITH INPUT OF 300 000 BTU HR OR GREATER MODELS WITH IID INTERMITTENT IGNITION SYSTEM AND OPTIONAL VENT DAMPER WIRING DIAGRAMS FOR STEAM BOILERS WITH INPUT UNDER 300 000 BTU HR MODELS WITH IID INTERMITTENT IGNITION SYSTEM AND 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 VENT DAMPER AND ELECTRONIC L W C O BOILERS UNDER 300 000 BTU HR INPUT WARNING BLOCKED VENT SAFETY SWITCH MUST BE MOUNTED TO DRAFT HOOD BEFORE OPERATING THE BOILER SEE INSTRUCTION MANUAL GG 40 BEFORE INSTALLING VENT DAMPER READ WARNING LABEL ON THIS BOILER AND VENT DAMPER READ SLANT FIN VENT DAMPER INSTALLATION INSTRUC
4. M 10 Improper controls 12 Safety pilot out or flame too low Gas supply valve shut off Electric switch open Blown or defective line fuse Operating or limit control contacts open or dirty Defective gas valve or pressure regulator or plugged bleed line Defective low voltage transformer Obstruction at main burner orifice Break in wiring or loose contact at control terminals Improper wiring Rollout or blocked vent safety switch open REMEDY 1 Check clean re light See instructions 2 Open gas valve s 3 Close switch 4 Replace fuse 5 Check control Clean contacts or replace control 6 Repair or replace 7 Replace aquastat 8 Check clean and reinstall 9 Check with test light and correct 10 Check and correct in accordance with wiring diagrams included with appliance instructions 11 Install proper controls 12 Replace rollout switch inspect flue passages prior to replacement or reset blocked vent safety switch by depressing the reset button BURNERS WILL NOT SHUT OFF CAUSE 1 2 Defective operating control gas valve or high limit control Improper wiring or short circuit REMEDY 1 Check repair or replace 2 Check wiring and controls FLASH BACK BURNING AT ORIFICES CAUSE REMEDY 1 Manifold gas pressure too low 1 Adjust to proper manifold pressure 2 Improper primary air adjustment 2 Adjust air to produce soft clean flame 3
5. 3 times Thereafter at least once a week 2 As boiler water circulates through the float chamber dirt or other sediment may be deposited This chamber is extra deep But the only sure way to keep any accumula tion from interfering with float action is to blow down or flush out the control once a week Do it while boiler is in operation First note water level in gauge glass Open blow off valve at bottom of control water will pour out flushing away sediment Drain until water is clear about a pail then close valve If level in gauge glass has dropped add water to boiler to restore level 13 Steam controls assembly Ht PRESSURE LIMIT NIPPLE VA x CLOSE TEE AAA 2 RAS 3 NOTE Opening blow off valve checks cut off operation too As float drops with falling water level burner will stop After valve is closed and normal operating conditions restored burner will resume firing 4 Be sure that it is the low water cut off and not the room thermostat pressure cut out energy cut off or other con trol that has shut off the burner PRESSURE CONTROL CHECK OUT A Check burner to be certain it is ready for firing DO NOT FIRE into an empty boiler B Set thermostat high enough for boiler to make steam Set the pressure control down to its lowest setting As the boiler starts to produce steam the steam pressure will start to build The burner will shut off when the steam pressure exceeds
6. A 120V BLK HOT FO BLOCKED VENT EMERGENCY SAFETY SWITCH SWITCH P ELECTRONIC LWCO THERMOSTAT PLUG 609 Ek 999 RECEPTACLE LO LIMIT P SCREW TERMINALS TANKLESS ONLY T THERMOSTAT ALARM OR WATER FEEDER WIRE NUT IF USED PRESSURE CUT OUT PRESSURE CUT OUT FOR McDONNNELL amp MILLER L W C O PS 802 24 AND WATER FEEDER WF 2 U 24 ONLY HOT NEUTRAL BLK WHITE HOT NEUTRAL BLK WHITE EMERGENCY E SWITCH 2 THERMOSTAT 4 EMERGENCY SWITCH THERMOSTAT CUT OUT 2H LO LIMIT PRESSURE ROLL OUT SWITCH 1 BLOCKED VENT SAFETY SWITCH SLANTEN ALARM OR VENT DAMPER 1 _ WATER FEEDER IF USED TERMINALS MARKING SHOWN 4 ARE FOR BOILER HARNESS MALE PLUG FOR McDONNNELL amp MILLER L W C O PS 802 24 AND WATER FEEDER WF 2 U 24 ONLY WIRE LEGEND 2 4 FACTORY WIRED OO WIRE ENTRANCE FIELD CONNECTED ENDS POLARIZED FACTORY SUPPLIED Os CONNECTORS FIELD CONNECTED FIELD SUPPLIED RECEPTACLE WIRE LEGEND FACTORY WIRED F ELD CONNECTED FACTORY SUPPLIED FIELD CONNECTED FIELD SUPPLIED A PROVIDE DISCONNECT MEANS amp OVERLOAD
7. If the boiler has an input of 300 000 Btu hr or greater cut the RED wire connected between numbers 3 and 4 of RECEPTACLE A the only wire connected to this receptacle and then disconnect 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 fig ures 4 9 The vent damper must be installed so that the damper position indicator is in a visible location after installation for position indicator description The arrow imprint on the damper should point in direction of vent gas flow towards chimney Re assemble the vent pip ing Be sure the vent damper is well seated and fas tened with 3 sheet metal screws Screws should be no longer than 1 2 inch 3 Be sure that undersized vent pipe does not block move ment of damper vane 4 Boilers that may have vent damper are factory wired with plug and RECEPTACLE A To install the vent damper all that is required is removal of the RECEPTA CLE A and connection of the vent damper harness to the boiler plug Remove RECEPTACLE A from job site and discard Boilers that must have a vent damper are factory wired with plug only a Attach the flexible metallic conduit vent damper har ness to the right hand side of the jacket by passing the free end of the harness through the 7 8 diameter hole in the top of the jacket and using the BX con nector
8. areas Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure Horizontal breeching or vent pipe should be as high as possible con sistent with codes so that vertical vents from appliances will have a high rise above draft diverter openings All horizontal runs must slope upwards not less than 1 4 inch per foot of run Horizontal portions of the venting system must be sup ported to prevent sagging by securing each joint with metal screws and by providing hangers spaced no greater than 5 feet apart D Vent or breeching into chimney should not be inserted past the inside wall of the chimney liner E All venting means should be inspected frequently See Care and Maintenance and separate User s Information Manual MINIMUM CLEARANCE MINIMUM CLEARANCE on threads must be resistant to the action of liquefied petro leum gases The gas supply line to the boiler should be run directly from the meter for natural gas or from the fuel tank for L P propane gas See page 2 for location of union and manual main shut off valve that may be specified locally Selecting pipe size for natural gas 1 Measure or estimate the length of piping from the meter to the installation site 2 Consult gas supplier for heating value of gas BTU cu ft 3 Divide boiler rated input by heating value to find gas flow in piping cu ft per h
9. Ste Gas Circulator Pilot Manifold Assembly FRONT VIEW RIGHT SIDE All GG and GX H GG GX H PT GALAXY Tankless T 208 Pressure apping is and i pressure auge an Hi Press Tapping 99 Low Water e Cut off Cutoft o Float ut o Probe ype Water Level Water Gauge Gauge RIGHT SIDE RIGHT SIDE GX H PZT PPZT GX H PZ SERIES s WATER BOILERS DIMENSIONS IN INCHES GG 225H GG 250H 66 275 66 300 66 325 66 350 GG 350H GG 375H GG 399H GG 75H GG 100H GG 125H 19 19 13 13 6 53 19 1 rs XT s 13 8 14 14 2 9 8 14 14 2 94 1 28 9 1 28 9 L EXHA 100 GXH 105 GXHA 20 GXH 125 18 4 to 9 Install Manual Shut Off Valve 5 ft Above When Required Local Ground Joint LEFT SIDE All GG and GX H FRONT VIEW All GG and GX H ORIFICE SIZES indicated for Sea Level are factory installed in boiler unless otherwise specified by the local authority See VII page 12 for burner input adjustment GAS VALVE CONNECTION Size is 1 2 f p t for all sizes up to and including GG 225 and GX 225 Larger boilers gas valves may be 3 4 or 1 2 depending upon configuration natural L P standing pilot IID COMBUSTIBLE FLOOR KIT increases all height dimensions by 1 RAISED SLAB When mounting boiler on a raised slab the slab must extend at least 2 be
10. 10 and Appendix G of the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition which will be referred to as the National Fuel Gas Code Local codes apply If a masonry chimney is exposed to the outdoors on one or more sides below the roof line exterior chimney ONE of the following options apply 1 Chimney must be re lined with a UL LISTED metallic liner When this is done the chimney will be considered NOT exposed to the outdoors and the requirements of the National Fuel Gas Code for NON exposed chimneys and or local codes will apply 2 If an exposed tile lined chimney is to be used WITHOUT a UL LISTED metallic liner the boiler must first meet the requirements of the following tables and paragraphs of the National Fuel Gas Code For Single Galaxy Boiler Paragraph 10 1 9 and table 10 11 Il For multiple appliances Paragraph 10 2 18 and table 10 12 or 10 13 if applicable In addition all requirements of Part 7 Part 10 and Appendix G of the National Fuel Gas Code and or local codes apply B If an existing boiler is removed from a common venting sys tem the common venting system may be too large for prop er venting of the remaining appliances connected to the common vent Follow the test procedure shown in Appendix A on page 28 of this manual to insure proper operation of venting system and appliances C Inspect for proper and tight construction Any restrictions or obstructions must be removed An existin
11. DRAFT HOOD BEFORE OPERATING THE BOILER SEE INSTRUCTION MANUAL GALAXY GG 40 BEFORE INSTALLING VENT DAMPER READ WARNING LABEL ON THIS BOILER AND VENT DAMPER READ SLANT FIN VENT DAMPER INSTALLATION INSTRUCTIONS FOR PROPANE USE S8600M OR S8670E FOR NATURAL GAS S8600F S8600M OR S8670E SLANT FIN VENT DAMPER 4 1 3 ya FLEX METALLIC CONDUIT VENT DAMPER HARNESS SUPPLIED WITH VENT DAMPER RECEPTACLE B CONNECTS TO MALE PLUG ON ADAPTER HARNESS MALE PLUG N 58600 OR 8670 A 24V GND n HOTBLK Co EMERGENCY RED SWITCH BLK 11 ROLL OUT AND LOW LIMIT BLOCKED VENT IF USED SAFETY NEUTRAL WHITE E 24V 120V SWITCHES PV ES OnF Q es THERMOSTAT AV ELECTRIC IGNITION IGNITION CABLE PRESSURE CUT OUT PV w GND GAS VALVE PILOT GAS RED NEUTRAL WHITE EMERGENCY SWITCH VALVE COIL MV MV PV e LIGHTER p ROLL OUT AND BLOCKED 4 VENT SAFETY SWITCHES PRESSURE CUT OUT VENT DAMPER TERMINALS MARKING SHOWN ARE FOR BOILER HARNESS MALE PLUG
12. FOR LEAST 75 IF ANY OF THE ORIGINAL WIRE as TED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 105 OR ITS EQUIVALENT IF THE RED CABLE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH POWER LIMITED FIRE PROTECTIVE 18 2 CABLB 41 1670 GALAXY WIRING DIAGRAMS FOR HOT WATER BOILERS WITH INPUT UNDER 300 000 BTU HR MODELS WITH IID INTERMITTENT IGNITION SYSTEM AND VENT DAMPER WIRING DIAGRAMS FOR HOT WATER BOILERS WITH INPUT OF 300 000 BTU HR OR GREATER MODELS WITH IID INTERMITTENT IGNITION SYSTEM AND 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 HOT WATER S BOILER WITH 24V HONEYWELL INTERMITTENT IGNITION VENT DAMPER AND HI LIMIT CONTROL CONSTANT CIRCULATION BOILERS UNDER 300 000 BTU HR INPUT WARNING BLOCKED VENT SAFETY SWITCH MUST BE MOUNTED TO DRAFT HOOD BEFORE OPERATING THE BOILER SEE INSTRUCTION MANUAL GALAXY GG 400 BEFORE INSTALLING VENT DAMPER READ WARNING LABEL ON THIS BOILER AND VENT DAMPER READ SLANT FIN VENT DAMPER INSTALLATION INSTRUCTIONS FOR PROPANE USE S8600M OR 58670 FOR NATURAL GAS S8600F 58600 OR S8670E NEUTRAL WHITE SLANT FI IN VENT DAMPER 4 3 AL FLEX METALLIC CONDUIT TBAHHM VENT DAMPER HARNESS SUPPLIED WIT
13. Gas regulator bleed too slow 3 Adjust bleed opening 4 Burrs on orifice 4 Remove burrs 5 Improperly drilled orifice plugs 5 Install orifice plugs with proper drilling 6 Leaking automatic gas valve 6 Repair or replace 7 Adverse draft condition in boiler room 7 Check air supply and venting system 8 Low main gas pressure 8 Contact utility 9 Safety pilot improperly installed 9 Correct to manufacturer s recommendations DELAYED IGNITION CAUSE REMEDY 1 Pilot flame too low 1 Increase gas supply to pilot 2 Pilot burner ports or pilot orifice clogged 2 Clean ports or orifices 3 Burners or orifices out of alignment 3 Realign burners or manifold 4 Excessive primary air 4 Adjust primary air shutters 5 Excessive burner input 5 Check and reduce to input shown on rating plate 6 Adverse draft condition in boiler room 6 Check air supply and venting system FUMES AND GAS ODORS CAUSE REMEDY 1 Leaks in gas piping or accessories 1 Locate leaks and repair 2 Gas leaks in service line or meter connections 2 Close service supply valve shut down appliance and 3 Blocked chimney notify utility 4 Boiler flueways blocked with soot 3 Check and repair chimney 5 Undersized breeching or too many turns in breeching 4 Clean flueways and adjust burners as described in the 6 Adverse draft condition in boiler room installation instructions 7 Overfiring 5 Check manufacturer s recommendations 6 Check air supply and ve
14. MILLER LW C O PS 802 24 AND WATER FEEDER WF 2 U 24 ONLY WIRE LEGEND 2 FACTORY WIRED WIRE STEAM PZ PZT AND PPZT BOILER WITH CONTINUOUS PILOT OPTIONAL VENT DAMPER AND MM 67 L W C Q LO LIMIT IF WITH TANKLESS BOILERS WITH 300 000 BTIU HR INPUT WARNING BLOCKED VENT SAFETY SWITCH MUST BE MOUNTED TO DRAFT HOOD BEFORE OPERATING THE BOILER SEE INSTRUCTION MANUAL 66 40 BEFORE INSTALLING VENT DAMPER READ WARNING LABEL ON THIS BOILER AND VENT DAMPER READ SLANT FIN VENT DAMPER INSTALLATION INSTRUCTIONS OPTIONAL VENT DAMPER FLEX METALLIC CONOUIT IT DAMPER HARNESS SUPPLIED WITH VENT DAMPER RECECPTACLE A HARNESS MALE PLUG WHITE NEUTRAL BLK HOT H N BLOCKED VENT SAFETY SWITCH LO LIMIT TANKLESS ONLY THERMOSTAT L W C 0 MM 67 PRESSURE 0 EMERGENCY A ITCH THERMOSTAT L LO LIMIT PRESSURE ROLL OUT WIRE LEGEND FIELD CONNECTED FACTORY SUPPLIED FIELD CONNECTED ENDS POLARIZED 1 O CONNECTORS FIELD SUPPLIED RECEPTACLE PROVIDE DISCONNECT MEANS amp OVERLOAD PROTECTION AS REQUIRED IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 105 OR ITS EQUIVALENT IF THE WIRES MARKED P MUST BE REPLACED THEY MUST BE REPLACED WITH POWER LIMITED FIRE PROTECTIVE CABLE TERMINALS MARKI
15. PROTECTION AS REQUIRED UI IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST Bt REPLACED IT MUST BE REPLACED WITH TYPE 105 C OR ITS EQUIVALENT IF THE WIRES MARKED P MUST BE REPLACED THEY MUST BE REPLACED WITH POWER LIMITED FIRE PROTECTIVE CABLE 3 0 5 SHOWN WHEN BOILER WATER IS AT NORMAL LEVEL GALAXY 41 1191B WIRE ENTRANCE ENDS POLARIZED PROVIDE DISCONNECT MEANS amp OVERLOAD PROTECTION AS REQUIRED IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 105 C OR ITS EQUIVALENT IF THE WIRES MARKED P MUST BE REPLACED THEY MUST BE REPLACED WITH POWER LIMITED FIRE PROTECTIVE CABLE TERMINALS MARKING SHOWN IN CIRCLES ARE FOR McDONNELL amp MILLER L W C O THOSE NOT IN CIRCLES ARE FOR HYDROLEVEL SAFGARD CONTACTS SHOWN WHEN BOILER WATER IS AT NORMAL LEVEL GALAXY 41 1190D GALAXY 21 WIRING DIAGRAMS FOR STEAM BOILERS WITH INPUT OF 300 000 BTU HR MODELS WITH CONTINUOUS PILOT AND 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 CONTINUOUS PLOT OPTIONAL VENT DAMPER AND ELECTRONIC LW CO BOILERS WITH 300 000 BTU HR INPUT WARNING BLOCKED VENT SAFETY SWITCH MUST BE MOUNTED TO DRAFT HOOD BEFORE OPERATING THE BOILER SEE INSTRUCT
16. corrosion and other deficiencies which could cause an unsafe condition c Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maxi mum speed DO NOT operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously e Test for spillage at the draft hood relief opening after 5 min utes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use g Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 latest edition When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined
17. harmful to skin eyes and clothing 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 IV TREATING WATER FOR CORROSION CONTROL This is not scale control A Prepare a boil out solution of caustic soda Proportions 1 Ib per 50 gallons of boiler water B Stir chemical in water until dissolved and pour into boiler through a top tapping Replace plug V FILLING AND VENTING THE STEAM BOILER A Refill the boiler to the indicated water line B Bring water to boiling temperature promptly C The boiler is now ready to be put into service or on standby VI INITIAL START Safe lighting and other performance criteria were met when testing various gas manifold and control assemblies used on the Galaxy Series boilers under the ANSI Z21 13b 1994 FIGURE 11 Pilot in Boiler Side View typical Aluminum Pilot Gas Tube Thermocoupie GALAXY INSTRUCTIONS Follow the lighting instructions that apply to the particular igni tion system equipped on this boiler Also see figures on page 2 for location of gas manifold gas valve and control assembly 1 Continuous Burning Pilot FOR BOILERS EQ
18. limit control for boilers equipped with 30 psi relief valves Boilers rated for a high er pressure and equipped with a matching relief valve may operate at a higher pressure but no higher than 5 psi below the relief valve opening pressure D Check for and repair any leaks before placing system in service Make sure that none of the automatic gas ignition system components are exposed to water 10 II CLEANING AND FILLING NEW STEAM BOILER Before using steam boiler A Check boiler to be certain it is ready for firing DO NOT FIRE into an empty boiler B Be prepared to heat raw water to at least 180 F as soon as it is introduced into the boiler This procedure will remove dissolved corrosive gases C Provide drain line with valve from boiler Use a bottom tap ping Line and drain must be suitable for handling caustic solution 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 Fill boiler to proper water line 2 Prepare a boil out solution of caustic soda NOTE Use CAUTION in handling chemicals Caustic soda is
19. pilot at pilot mount or disconnect thermocou ple and pilot gas line at gas valve before removing burn ers next to pilot Lift rear of burner and remove burner from orifice d Clean and replace burners and pilot Adjust burners as described on page 12 To clean burners run a clean flue brush up the tube until all foreign matter is removed WARNING The ceramic combustion chamber in the burner box contains crystalline silica Wear proper dust mask and gloves when servicing combustion chamber or burners Crystalline Silica has been identified as a carcino genic or possibly carcinogenic to humans 16 Boiler Cleaning IV V DRAFT HOOD JACKET TOP FLUE COLLECTOR FLUE COVER 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 auto matically If the high limit does not close the main gas valve the valve the high limit or the wiring is faulty Repair or replace immediately B Gas valve safety shutdown test 1 For boiler equipped with continuous burning pilot with main burners firing disconnect the thermocouple or thermopile generator from the gas valve The gas valve should immediately shut off the main burners and the pilot 2 For boilers equipped with Hone
20. the pressure setting plus differential if the control has this feature C Adjust the pressure control to a higher setting The higher setting should be above the steam pressure in the boiler This should turn the burner back on D Reset the pressure control as needed for the system The pressure control should be checked out at least twice a year Steam Controls Installation Instructions Steam kit components for Galaxy packaged models are packed as follows Low water cut off control electric installed Pressure gauge High pressure limit control Water level gauge Fittings Instruction sheet and assembly drawing Steam safety valve and 3 4 street coupling Drain cock Assembly above components exactly as shown Two 1 2 tappings are on right side of boiler for this assembly Two holes are pre punched in jackets ONOARON 14 Replacement of Steam Boilers Anytime an older steam boiler is removed from the heating sys tem 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 Therefore it is necessary when replacing a steam boiler to check the piping for blockage or restrictions Clean or replace the piping as required See special flushing instructions page 13 2 R
21. to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier To Turn Off Gas To Appliance Set the thermostat to lowest setting Turn off all electric power to the appliance if service is to be performed Remove control access panel Galaxy models only Turn gas control knob clockwise CUN to DO NOT force Replace control access panel Galaxy models only FIGURE 14 Gas Valve VR8204 and VR8304 e OFF GAS CONTROL KNOB SHOWN IN POSITION 12 VII 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 rat ing plate NOTE Gas pressure may be adjusted by turning pressure regulator screw on combination gas valve Turn clockwise to increase pressure counter clockwise to decrease pressure a Input for PROPANE is approximately at rating shown on rating plate when manifold pressure is 9 1 2 water column b Input for NATURAL GAS is approximately at rating when manifold pressure is 3 1 2 water column but should be checked on the gas meter Btuh Input Btuh cu ft x cu ft metered in minutes x 20 Example 1 For 1000 Btu cu ft gas this b
22. will cause bright orange flames Wait for dust to settle 3 For one burner close the air shutter until some of its flame jet tips turn yellow white indicating insufficient pri mary air Then open shutter until whitish tips disappear completely Set all burner shutters to the same opening Observe to make sure that no yellow white tips appear over any portion of the flame Small yellow tips at the pilot location are permitted NOTE This adjustment method gives MINIMUM primary air setting for safe combustion DO NOT attempt to make this adjustment unless burners are at operating tempera ture Adjustment should be made with jackets in final operating position Use of mirror may be helpful to observe flames Note that burner ports are on top of main burner tube FLAME TIPS EE AUN _ X Front back sliding primary air shutter locking screw on top BLUE FLAME BASE MANIFOLD C Main Burner Ignition Check out and Pilot Adjustment 1 The pilot flame must not smother or snuff out when test ed as follows a Main burner ignition from cold start repeat b Continued operation of main burner c Main burner ignition with appliance at maximum oper ating temperature after prolonged operation NOTE Observe operation of the pilot burner with appli ance doors in the final operating position Use of a mir ror may be helpful 2 Safety Shutdown Check out a Make certain the pilot burner holds in and the power pile val
23. 00F IGNITION TRIAL SYSTEM Y IGNITION SPARK CON SHUTOFF ide ie THE PILOT FLAME ESTABLISHED gt ee WAIT SEQUENCE REPEATS REMAINS OPEN UNTIL CONTINUOUSLY Y YES SYSTEM IS RESET SPARK GENERATOR OFF MAIN VALVE OPERATOR OPENS MODULE MONITORS PILOT FLAME Y WHEN THERMOSTAT IS SATISFIED OR WHEN HIGH LIMIT LOW LIMIT PRESSURE CUT OUT OR LOW WATER CUT OFF CON TACTS ARE OPEN VALVE OPERATORS CLOSE VENT DAMPER CLOSES CIRCULATOR OFF SYSTEM GOES TO STANDBY 18 WIRING DIAGRAMS FOR HOT WATER BOILERS WITH INPUT UNDER 300 000 BTU HR MODELS WITH CONTINUOUS PILOT AND 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 HOT WATER BOILER S AND ST WITH CONTINUOUS PILOT VENT DAMPER AND HI LIMIT CONTROL LO LIMIT IF W TANKLESS CONSTANT CIRCULATION BOILERS UNDER 300 000 BTU HR INPUT WARNING BLOCKED VENT SAFETY SWITCH MUST BE MOUNTED TO DRAFT HODD BEFORE OPERATING THE BOILER SEE INSTRUCTION MANUAL GALAXY 66 40 OR SENTRY 5 40 BEFORE INSTALLING VENT DAMPER READ WARNING LABEL ON THIS BOILER AND VENT DAMPER READ SLANT FIN VENT DAMPER INSTALLATION INSTRUCTIONS FLEX METALLIC CONDUIT HARNESS WITH VENT DAMPER RECEPTACLE B CONNECTS TO MALE QN ADAPTER HARNESS 1 ROLL OUT AND BLOCKED VENT SAFETY SWIT
24. BURNER ELECTRIC al IGNITION IGNITION PILOT CABLE GND GAS VALVE PILOT GAS MV RED NEUTRAL WHITE THERMOSTAT CONTROLER HIGH LIMIT WIRE LEGEND FACTORY WIRED FIELD CONNECTED FACTORY SUPPLIED FIELD CONNECTED FIELD SUPPLIED GAS VALVE I a VALVE GND 08 58670 PILOT LIGHTER SLANTEN VENT DAMPER TERMINALS MARKING SHOWN ARE FOR BOILER HARNESS MALE PLUG ROLL OUT AND BLOCKED VENT SAFETY SWITCHES WIRE ENTRANCE ENDS POLARIZED CONNECTORS RECEPTACLE A PROVIDE DISCONNECT MEANS amp OVERLOAD PROTECTION AS REQUIRED FOR FIELD WIRED CONNECTIONS USE WIRING MATERIAL RATED FOR AT LEAST 75 C IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 105 C OR ITS EQUIVALENT IF THE WIRES MARKED MUST BE REPLACED THEY MUST BE REPLACED WITH POWER LIMITED FIRE PROTECTIVE CABLE GALAXY 41 1532 26 PUMP OR VALVE ZONING OF WATER COMBINATION CONTROLS WITH TO ADDITIONAL RB45A RELAYS FOR OTHER ZONES RB45A RELAY i gt ZONE LOW VOLTAGE GAS VALVE E LOW VOLTAGE ZONE 1 THERMOSTAT L HOT 02 JN POWER SUPFLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED USE TYPE 105 C WIRE OR EQUIVA
25. CH MUST BE MOUNTED TO DRAFT HOOD BEFORE OPERATING THE BOILER SEE INSTRUCTION MANUAL GALAXY 66 40 BEFORE INSTALLING VENT DAMPER READ WARNING LABEL ON THIS BOILER AND VENT DAMPER READ SLANT FIN VENT DAMPER INSTALLATION INSTRUCTIONS OPTIONAL VENT DAMPER SLANT FIN 1 FLEX METALLIC CONDUIT HARNESS SI WITH VENT DAMPER 1 RECEPTACLE B CUNMECTS TO MALE PLUG ON ADAPTER HARNESS RED 1 2 3 i THI AT 5 FOR CIRCULATOR LO LIMIT FOR TANKLESS ONLY 2 EMERGENCY A SWITCH BLOCKEI SAFETY SWITCH TERMINALS MARKING SHOWN ILER HARNESS WIRE LEGEND 4 FACTORY WIRED O WIRE ENTRANCE 1 3 CONNECTED ENDS POLARIZED FACTORY SUPPLIED 1 CONNECTORS FIELD SUPPLIED PLUG RECEPTACLE PROVIDE DISCONNECT MEANS amp OVERLOAD PROTECTION AS REQUIRED FOR FIELD WIRED CONECTIONS USE WIRING MATERIAL RATED FOR AT LEAST 75 IF ANY THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 105 C OR ITS EQUIVALENT IF THE RED CABLE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH POWER LIMITED FIRE PROTECTIVE 18 2 CABLE X TERMINALS LETTERS AND 8 AND JUMPER APPLY ONLY TO COMBINED HI LIMIT LOW LIMIT CONTROLS GALAXY 41 1282 GALAXY WIRING DIAGRAMS FOR STEAM BOILERS WITH INPUT UNDER 300 000 BTU HR MODELS WITH CONTINUOUS PILOT AND VENT DAMPER CAUTION Label all wires pr
26. CHES 56 XFOR RCT ONLY CIRCULATOR LO LIMIT FOR TANKLESS ONLY LO LIMIT WIRE LEGEND FACTORY WIRED CONNECTED FACTORY SUPPLIED FIELD CONNECTED FIELD SUPPLIED kp 3 19 CONNECTORS PLUG RECEPTACLE TYPE 105 C OR ITS EQUIVALENT IF THE RED CABLE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH POWER LIMITED FIRE PROTECTIVE 18 2 CABLE X TERMINALS LETTERS R AND AND JUMPER APPLY ONLY TO COMBINED HI LIMIT LOW 1817 CONTROLS PLUG AND RECEPTACLE ARE IN CONTROL BOX ON SENTRY SERIES BOILER FOR SENTRY BOILERS ONLY IF THE WIRES MARKED P MUST BE REPLACED IT MUST BE REPLACED WITH POWER LIMITED FIRE PROTECTIVE CABLE GALAXY SENTRY 41 1199 C HOT WATER P 8 PT BOILER WITH CONTINUOUS PILOT VENT DAMPER AND COMBINATION CONTROL INTERMITTENT CIRCULATION BOILER DER 300 000 BTU HR INPUT WARNING BLOCKED VENT SAFETY SWITCH MUST BE MOUNTED TO DRAFT HOOD BEFORE PRA um BOILER SEE INSTRUCTION MANUAL GALAXY 66 40 OR SEN 4 BEFORE INSTALLING VENT DAMPER READ WARNING LABEL ON THIS BOILER AND VENT DAMPER READ SLANT FIN VENT DAMPER INSTALLATION INSTRUCTIONS CONTROLLER x 120V 5 24V TERMOSTAT CIRCULATOR 5 COMBINATION CONTROL 3 4 RECEPTACLE 8 CONNECTS TO MALE ON ADAPTER HARNESS NEUTRAL EMERGENCY WH
27. D BLOW OUT THERMOCOUPLE WILL SHUT OFF MAIN BURNERS Y WHEN THERMOSTAT IS SATISFIED OR WHEN HIGH LIMIT LOW LIMIT PRESSURE CUT OUT OR LOW WATER CUT OFF CONTACTS ARE OPEN MAIN VALVE OPERATOR CLOSES VENT DAMPER CLOSES CIRCULATOR OFF SYSTEM GOES TO STANDBY WITH LIT PILOT SEQUENCE OF OPERATION FOR GALAXY BOILERS EQUIPPED WITH HONEYWELL INTERMITTENT PILOT IGNITION SYSTEM FOR DIAGRAMS SHOWN ON PAGES 22 24 THERMOSTAT CALLS LOW LIMIT FOR TANKLESS COIL CALLS FOR HOT WATER EJ lt HOT WATER BOILERS EQUIPPED HIGH LIMIT CONTACTS CLOSED NO gt 7 LOW WATER CUT OFF WHEN USED CONTACTS CLOSED gt NO fp UNLESS LOW MIT CATA OND PRESSURE CUT OUT WHEN USED CONTACTS CLOSED IS CALLING FOR HOT WATER YES T VENT DAMPER RELAY ENERGIZED VENT DAMPER MOTOR MOVES OPEN VENT DAMPER VENT DAMPERS END SWITCH CLOSES L P PROPANE GAS y S8600M AND 58670 IGNITION TRIAL CONTIN IGNITION CONTROL ENERGIZED UES FOR 90 SECONDS AFTER TRIAL FOR IGNI y TION SYSTEM SHUTS OFF AFTER 5 MINUTES MOD SPARK GENERATOR MODULE POWERED ULE RE INSTATES TRIAL S8600F OR S8600M IGNITION SPARK STARTS AND PILOT VALVE OPERATOR OPENS FOR IGNITION IF PILOT 586705 IGNITION SPARK AND PILOT VALVE OPERATOR DELAYED FOR 30 70 SECONDS FLAME NOT ESTABLISHED NATURAL GAS S86
28. DAMPER SLANT FIN VENT DAMPER FLEX METALLIC CONDUIT 4 3 RECEPTACLE A 2 VENT DAMPER HARNESS SUPPLIED MALE PLUG WITH VENT DAMPER 1 3 l RECEPTACLE B CONNECTS TO MALE PLUG ON ADAPTER HARNESS MOTI3A WHITE NEUTRAL VIOLET N 120 24 HOT BLK Ho e 58600 OR 58670 24V GND MV OA 2 EMERGENCY BLK SWITCH LOW LIMIT IF USED BLOCKED VENT SAFETY 1 2 KO SWITCH i SPARK c4 i gt Q GND H e or BURNER MM 67 LWCO THERMOBTAT 250 C BLK ELECTRIC f y IGNITION IGNITION PILOT CABLE PRESURE CUT OUT p GND EY T GAS VALVE PILOT GAS MV RED HOT NEUTRAL BLK WHITE A L EMERGENCY SWITCH 1 GAS VALVE Or ROLL OUT AND BLOCKED PRESURE CUT OUT SLANTIPIN 1 VENT SAFETY SWITCHES VENT DAMPER TERMINALS MARKING SHOWN ARE FOR BOILER HARNESS MALE PLUG coyracTs SHOWN WHEN BOILER WATER IS AT NORMAL LEVEL WIRE LEGEND EU 2 4 FACTORY WIRED C WIRE ENTRANCE FIELD CONNECTED ENDS POLARIZED FACTO
29. EPLACED WITH TYPE 105 C OR ITS EQUIVALENT IF THE WIRES MARKED P MUST BE REPLACED THEY MUST BE REPLACED WITH POWER LIMITED FIRE PROTECTIVE CABLE GALAXY 41 1531 HOT WATER S BOILER WITH 24V HONEYWELL INTERMITTENT IGNITION OPTIONAL VENT DAMPER AND HI LIMIT CONTROL CONSTANT CIRCULATION BOILERS WITH INPUT OF 300 000 BTU HR OR GREATER WARNING BLOCKED VENT SAFETY SWITCH MUST BE MOUNTED TO DRAFT HOOD BEFORE OPERATING THE BOILER SEE INSTRUCTION MANUAL GG 40 BEFORE INSTALLING OPTIONAL VENT DAMPER READ WARNING LABEL ON THIS BOILER AND VENT DAMPER READ SLANT FIN VENT DAMPER INSTALLATION INSTRUCTIONS FOR PROPANE USE S8600M OR S8670E ONLY FOR NATURAL GAS S8600F S8600M OR S8670E OPTIONAL VENT DAMPER SLANT FIN VENT DAMPER 8 3464 2 FLEX METALLIC CONDUIT VENT DAMPER HARNESS SUPPLIED WITH VENT DAMPER RECEPTACLE A MALE PLUG RECEPTACLE B CONNECTS TO MALE PLUG ON ADAPTER HARNESS WHITE NEUTRAL al N AN AE Ld Wa p HOTBLK SWITCH EMERGENCY SWITCH 24V THERMOSTAT L HIGH LIMIT LINE VOLTAGE CIRCULATOR FOR HOT WATER BOILER HOT lt _ EMERGENCY SWITCH 4 ORNO 58600 OR 8670 24V GND e RED BLOCKED VENT SAFETY SWITCH Q GND
30. EPLACEMENT 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 GG 10PL for Galaxy GG Series GX 10PL for Galaxy GX 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 Only simple easily identified controls and parts may be obtained locally All other controls and parts should be identified by and ordered from Slant Fin Relief Safety valves must be ASME rated for the pressure and gross output of the boiler When ordering replacement parts specify the boiler model number serial number and gas by name natural or propane For replacement parts heating contractors should contact their Slant Fin boiler distributor GALAXY APPENDIX A 29 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 com mon 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 b Visually inspect the venting system for proper size and hori zontal pitch and determine there is no blockage or restric tion leakage
31. H VENT DAMPER RECEPTACLE B CONNECTS TO MALE PLUG ON ADAPTER HARNESS N MALE PLUG VIOLET MOTIA 24 HOT EMERGENCY SWITCH A rora 24 OR CONTROLER 1 RED S8600 OR 88670 24V GND ROLL OUT AND BLOCKED VENT SAFETY SWITCHES HIGHLIMIT LINE VOLTAGE CIRCULATOR FOR HOT WATER BOILER HOT BLK A EMERGENCY SWITCH PILOT ELECTRIC IGNITION IGNITION CABLE GND PILOT GAS GAS VALVE mvv RED NEUTRAL WHITE THERMOSTAT OR CORONTROLER HIGH LIMIT WIRE LEGEND FACTORY WIRED FIELD CONNECTED FACTORY SUPPLIED FIELD CONNECTED FIELD SUPPLIED SLANTIFIN VENT DAMI TERMINALS MARKING SHOWN ARE FOR BOILER HARNESS MALE PLUG GAS VALVE ROLL OUT AND BLOCKED VENT SAFETY SWITCHES PER oF 6 GND PV Mv NN S8600 0858670 PILOT 2 4 WIRE ENTRANCE O ENDS POLARIZED 1 3 CONNECTORS RECEPTACLE PROVIDE DISCONNECT MEANS amp OVERLOAD PROTECTION AS REQUIRED IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE R
32. INSTALLATION INSTRUCTIONS T CONTROLLER 9 OR 120 24V THERMOSTAT CIRCULATOR 2 COMBINATION CONTROL CEPTACLE B TO MALE PLUG ADAPTER HARNESS RED SLANT FIN FLEX METALLIC VENT DAMPER COND FOR L8148E ONLY OPTIONAL VENT DAMPER 48 NEUTRAL EMERGENCY WHITE A SWITCH THERMOSTAT FOR C LIHET 5 a 4 5 63 ROLL OUT lura 1 89 TERMINALS MARKING wn ARE F R BOILER HARNESS PLUG IKI fan FOR L8148E ONLY WIRE LEGEND a gt WIRED WIRE ENTRANCE FIELD CONNECTED OO ENDS POLARIZED FACTORY SUPPLIED 3 CONNECTORS FIELD CONNECTED PLUG RECEPTACLE PROVIDE DISCONNECT MEANS amp OVERLOAD PROTECTION AS REQUIRED FOR FIELO WIRED CONECTIONS USE WIRING MATERIAL RATED FOR AT LEAST 75 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 105 ITS EQUIVALENT IE THE CABLE AS SUPPLIES WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH POWER LIMITED FIRE PROTECTIVE 18 2 CABLE GALAXY 41 1261 HOT WATER BOILER S AND ST WITH CONTINUOUS PILOT DPTIONAL VENT DAMPER AND HI LIMIT CONTROL LO LIMIT IF W TANKLESS CONSTANT CIRCULATION BOILERS WITH 300 000 BIU HR INPUT WARNING BLOCKED VENT SAFETY SWIT
33. ION MANUAL GG 40 BEFORE INSTALLING VENT DAMPER READ WARNING LABEL ON THIS BOILER AND VENT DAMPER READ SLANT FIN VENT DAMPER INSTALLATION INSTRUCTIONS OPTIONAL VENT DAMPER SLANT FIN VENT DAMPER I FLEX CONDUIT VENT DAMPER HARNESS SUPPLIED WITH VENT DAMPER E RED TCHAD RECECPTACLE A RECEPTACLE B CONNECTS TO MALE PLUG MALE PLUG ON ADAPTER HARNESS MONIA ROLL OUT lt SWITCH RED N WHITE NEUTRAL CABLE A 120V H Y BLK HOT EMERGENCY BLOCKED VENT SWITCH SAFETY SWITCH VIOLET ELECTRONIC LWCO THERMOSTAT PLUG OO n SCREW TERMINALS 2 009809 Y Y OR FK T RECEPTACLE pUMPER 1 5 00 W WATER FEEDER IF USED WIRE NUT PRESSURE CUT OUT FOR McDONNNELL amp MILLER L W C O PS 802 24 AND WATER FEEDER WF 2 U 24 ONLY NEUTRAL WHITE EMERGENCY SWITCH VA A AAJ 2 BERAR 24V PRESSURE THERMOSTAT ONO CUT OUT ROLL OUT SWITCH BLOCKED VENT SLANT FIN ALARM OR VENTDAMPER L _ SAFETY SWITCH WATER FEEDER IF USED TERMINALS MARKING SHOWN ARE FOR BOILER HARNESS MALE PLUG FOR McDONNNELL amp
34. ITE SWITCH HERMOSTAT FOR CIRC LO 18124 santin VERF 817685 TERMINALS MARKING SHOHN ILER HARNESS 1 1 K 318 08 FOR 81485 ONLY WIRE LEGEND FACTORY WIRED T FIELD CONNECTED 00 ENDS POLARIZED ee FIELD SUPPLIED RECEPTACLE TYPE 105 C ITS EQUIVALENT IF THE RED CABLE Fg SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH POWER LIMITED FIRE PROTECTIVE 18 2 CABLE XX PLUG RECEPTACLE ARE IN COMBINATION CONTROL BOX ON SENTRY SERIES BOILERS FOR SENTRY BOILERS ONLY IF THE MIRES MARKED P MUST BE REPLACED IT MUST BE REPLACED WITH POWER LIMITED FIRE PROTECTIVE CABLE GALAXY SENTRY 41 1198 C GALAXY GALAXY 19 WIRING DIAGRAMS FOR HOT WATER BOILERS WITH INPUT OF 300 000 BTU HR MODELS WITH CONTINUOUS PILOT AND 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 HOT WATER P amp PT BOILER WITH CONTINUOUS PILOT OPTIONAL VENT DAMPER AND COMBINATION CONTROL INTERMITTENT CIRCULATION BOILERS WITH BTU HR INPUT WARNING BLOCKED VENT SAFETY SWITCH MUST BE MOUNTED TO DRAFT HOOD BEFORE OPERATING THE BOILER SEE INSTRUCTION MANUAL GALAXY GG 40 BEFORE INSTALLING VENT DAMPER READ WARNING LABEL ON THIS BOILER AND VENT DAMPER READ SLANT FIN VENT DAMPER
35. IVALENT IF THE WIRES MARKED P MUST BE REPLACED THEY MUST BE REPLACED WITH POWER LIMITED FIRE PROTECTIVE CABLE TERMINALS MARKING SHOWN IN CIRCLES ARE FOR McDONNELL amp MILLER CONTACTS SHOWN WHEN BOILER WATER IS AT NORMAL LEVEL GALAXY 41 1192 D L W C O THOSE NOT IN CIRCLES ARE FOR HYDROLEVEL SAFGARD CONTACTS SHOWN WHEN BOILER WATER IS AT NORMAL LEVEL GALAXY 41 1135F 24 WIRING DIAGRAMS FOR STEAM BOILERS WITH INPUT OF 300 000 BTU HR OR GREATER MODELS WITH IID INTERMITTENT IGNITION SYSTEM AND OPTIONAL VENT DAMPER GALAXY WIRING DIAGRAMS FOR HOT WATER BOILERS WITH INPUT OF 300 000 BTU HR OR GREATER MODELS WITH IID INTERMITTENT IGNITION SYSTEM AND 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 PZT AND PPZT BOILER WITH 24V HONEYWELL INTERMITTENT IGNITION OPTIONAL VENT DAMPER AND MM 67 L W C O LO LIMIT IF W TANKLESS BOILERS WITH INPUT OF 300 000 BTU HR OR GREATER WARNING BLOCKED VENT SAFETY SWITCH MUST BE MOUNTED TO DRAFT HOOD BEFORE OPERATING THE BOILER SEE INSTRUCTION MANUAL GG 40 BEFORE INSTALLING OPTIONAL VENT DAMPER READ WARNING LABEL ON THIS BOILER AND VENT DAMPER READ SLANT FIN VENT DAMPER INSTALLATION INSTRUCTIONS FOR PROPANE USE S8600M OR S8670E ONLY FOR NATURAL GAS S8600F S8600M OR S8670E OPTIONAL VENT
36. LENT Pump Zoning system using R845 Relay One R 845A needed for each circulator NOTE Pumps are powered from Total pump load must not exceed 7 4 amp rating of combination control pump switch ZONE THERMOSTAT OILERS TERMINALS 24 VOLT THERMOSTATS V8043F ENC SWITCH TO BURNER CIRCUIT AN Power SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED LIN maximun OF 2 V804Y S ACROSS 18148 USE AN AT 720 TRANSFORMER FOR EACH ADDITIONAL GROUP OF 3 OR LESS V804Y S USE TYPE 105 C WIRE OR EQUIVALENT Zone valve zoning system using Honeywell V8043F zone valves with standing pilot For intermittent ignition system IID a separate transformer should be utilized for ALL of the zone valves ZONE 2 THERMOSTAT ZONE CIRCULATOR POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED USE TYPE 105 C WIRE OR EQUIVALENT Pump zoning system using R8230C Relays For zoning diagrams combination controls without Tech Bulletin NOTE Pumps are powered from Tetal pump load must not exceed 7 4 amp rating of combination control pump switch CIRCULATOR Aas MANY AS FOUR R8230C RELAYS MAY BE POWERED BY THE 18148 OR L8124 GALAXY terminals and non combination control systems consult Slant Fin Zoning GALAXY GENERAL TROUBLESHOOTING GUIDE FOR SERVICEPEOPLE 27 BURNERS FAIL TO OPERATE CAUSE 1
37. NG SHOWN IN CIRCLES ARE FOR McDONNELL amp MILLER L W C O THOSE NOT IN CIRCLES ARE FOR HYDROLEVEL SAFGARD CONTACTS SHOWN WHEN BOILER WATER IS AT NORMAL LEVEL GALAXY 41 1263 A FACTORY WIRED FIELD CONNECTED a SRECI FIELD SUPPLIED PLUG RECEPTACLE WIRE ENTRANCE A PROVIDE DISCONNECT MEANS amp OVERLOAD PROTECTION AS REQUIRED IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 105 C OR ITS EQUIVALENT IF THE WIRES MARKEO MUST BE REPLACED THEY MUST BE REPLACED WITH POWER LIMITED FIRE PROTECTIVE CABLE 3K CONTACTS SHOWN WHEN BOILER WATER IS AT NORMAL LEVEL GALAXY 41 1264 WIRING DIAGRAMS FOR WATER BOILERS WITH INPUT UNDER 300 000 BTU HR MODELS WITH IID INTERMITTENT IGNITION SYSTEM AND VENT DAMPER GALAXY WIRING DIAGRAMS FOR STEAM BOILERS WITH INPUT UNDER 300 000 BTU HR MODELS WITH IID INTERMITTENT IGNITION SYSTEM AND 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 HOT WATER P 8 PT BOILER WITH 24V HONEYWELL INTERMITTENT IGNITION VENT DAMPER AND COMBINATION CONTROL INTERMITTENT CIRCULATION BOILERS UNDER 300 000 BTU HR INPUT WARNING BLOCKED VENT SAFETY SWITCH MUST BE MOUNTED TO DRAFT HOOD BEFORE OPERATING THE BOILER SEE INSTRUCTION MANUAL GALAXY GG 40 OR SENTR
38. OCATION HEATING BOILER Vertical Installation FIGURE 5 INSTALL HERE OPERATOR VENT DAMPER EXTERNAL DRAFT HOOD WRONG LOCATION gt MALE PLUG HEATING epe BOILER RECEPTACLE 8 INSTALL OPERATOR IN ANY POSITION AS SHOWN ABOVE DO NOT INSTALL THE OPERATOR ABOVE THE VENT PIPE TO AVOID EXCESSIVE HEAT OR BELOW THE VENT PIPE TO AVOID POSSIBLE CONDENSATE DAMAGE FIGURE 6 TO CHIMNEY WITH DAMPER OPEN 7 DIAK O 78 HOLE SIDE VIEW DAMPER SHOWN IN OPEN POSITION May be plugged with plug provided ONLY if boiler is equipped with an TOP VIEW intermittent ignition pilot DAMPER SHOWN IN CLOSED POSITION amp A i me ES ES ZZ FIGURE 7 SHEET METAL SCREWS FRONT SECTION FACTORY ASSEMBLED TO THE BOILER REAR SECTION SHIPPED WITH THE BOILER LOCKED VENT SAFETY SWITCH GALAXY FIGURE 8a amp 8b NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNI 2 A 2 A 4 2 2 2 LA 4 2 A LA 4 2 2 4 4 A 4 4 vA LA 2 7 2 2 2 RI ISSSSSSSSSSSSSSSSS L DXA H Horizontol Instollotion Verticol Instollotion of Vent Domper of Vent Domper FIGURE 9 CAUTION DO NOT USE ONE VENT DAMPER TO CONTROL TWO HEATING APPLIANCES DO pamper LJ LJ T HEATING HEATING HEATING HEATING APPLIANCE APPLIANCE APPLIANCE APPLIANCE WRONG WAY CORRECT WAY right hand corner of the boiler wiring diagram with the identical number on one of the diagrams in this manual
39. RY SUPPLIED 1 3 CONNECTORS _ FIELD CONNECTED FIELD SUPPLIED RECEPTACLE PROVIDE DISCONNECT MEANS amp OVERLOAD PROTECTION AS REQUIRED FOR FIELD WIRED CONNECTIONS USE WIRING MATERIAL RATED FOR AT LEAST 75 C IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 105 C OR ITS EQUIVALENT IF THE WIRES MARKED P MUST BE REPLACED THEY MUST BE REPLACED WITH POWER LIMITED FIRE PROTECTIVE CABLE GALAXY 41 1667U HOT WATER P AND PT BOILER WITH 24V HONEYWELL INTERMITTENT IGNITION OPTIONAL VENT DAMPER AND COMBINATION CONTROL INTERMITTENT CIRCULATION WARNING BLOCKED VENT SAFETY SWITCH MUST BE MOUNTED TO DRAFT HOOD BEFORE OPERATING THE BOILER SEE INSTRUCTION MANUAL 66 40 BEFORE INSTALLING VENT DAMPER READ WARNING LABEL ON THIS BOILER AND VENT DAMPER READ SLANT FIN VENT DAMPER INSTALLATION INSTRUCTIONS FOR PROPANE USE S8600M OR S8670E ONLY FOR NATURAL GAS S8500F S8500M OR 58670 OPTIONAL VENT DAMPER SLANT FIN VENT DAMPER BLOCKED VENT ROUT CAPT SHIICH S MARKING SHOWN BOILER HARNESS IRCULATOR WIRE LEGEND FACTORY WIRED too 290 WIRE ENTRANCE FIELD CONNECTED 60 ENDS POLARIZED EST m FIELD SUPPLIED PLUG RECEPTACLE N PROVIDE DISCONNECT MEANS amp OVERLOAD PROTECTION e REQUIRED FOR FIELD HIRED CONNECTIONS USE WIRING MATERIAL RATED
40. Slant Fin 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 LOW PRESSURE STEAM Models GXHA 100 through GXHA 200 INSTALLATION AND OPERATING INSTRUCTIONS Een La a anu tette PAGE H 2 Installation Requirements Boller Location u u 3 Boiler Foundation u U u 3 Chimney Requirements 3 Minimum 1 L R unde E 4 Cas PIPINO A X E E 4 Electrical Controls and Wiring sees 5 Boiler Room Air Supply and Ventilation 5 Draft Hood e 5 Piping at Boiler Weater Boilers 6 Steam Controls Assembly and Installation 6 Piping a Steam Boiler eene 6 7 dius m 8 9 Operating Instructions Filling and Venting Water 9 Initial Start Safety and Lighting Instructions 10 11 Burner Adjustment Checking Gas 12 Controls Safety Check
41. TIONS FOR PROPANE USE S8600M OR S8670E ONLY FOR NATURAL GAS S8600F S8600M OR S8670E SLANT FIN VENT DAMPER 4 3 FLEX METALLIC CONDUIT VENT DAMPER HARNESS SUPPLIED WITH VENT DAMPER RECEPTACLE B CONNECTS TO MALE PLUG ON ADAPTER HARNESS MALE PLUG E MOTBA WHITE NEUTRAL L ROLL OUT A 120V ESTO HOT BLK H e RED 8600 OR 58670 CABLE EMERGENCY P Y SWITCH AV BLOCKED VENT SAFETY SWITCH VIOLET 24V THERMOSTAT GND SPARK ELECTRONIC GND LWC BURNER screw PLUG 6 e TERMINALS 250 C 2 A IGNITION CABLE T RECEPTACLE A uen ELECTRIC IGNITION PILOT ALARMOR i WATER FEEDER PV IF USED WIRE NUT GAS VALVE PRESSURE CUT OUT PILOT GAS MV PV FOR McDONNNELL amp MILLER L W C O PS 802 24 AND WATER FEEDER WF 2 U 24 ONLY HOT BLK 1 EMERGENCY SWITCH L1 LWGO PRESSURE vii ROLL OUT BLOCKED VENT WATER FEEDER SLANT FIN SWITCH SAFETY SWITCH ORALARM VENT DAMPER IF USED TERMINALS MARKING SHOWN ARE FOR BOILER HARNESS MALE PLUG WIRE LEGEND 2 4 FACTORY WIRED
42. UIPPED WITH HONEYWELL GAS VALVE VR8200 AND VR8300 see figures 11 and 12 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 lit by hand When lighting the pilot follow these instructions exactly B BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS DO NOT try to light any appliance DO NOT touch any electric switch DO NOT use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions f you cannot reach your gas supplier call the fire department C Use only your hand to push in or turn the gas control knob NEVER use tools If the knob will not push in or turn by hand DON T try to repair it call a qualified ser vice technician Force or attempted repair may result in a fire or explosion D DO NOT use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been underwater Lighting Instructions STOP Read the safety information above on this page Set the ther
43. WIRE ENTRANCE FIELD CONNECTED ENDS POLARIZED FACTORY SUPPLIED 1 3 CONNECTORS FIELD CONNECTED FIELD SUPPLIED RECEPTACLE PROVIDE DISCONNECT MEANS amp OVERLOAD PROTECTION AS REQUIRED IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 105 C OR ITS EQUIVALENT IF THE WIRES MARKED P MUST BE REPLACED THEY MUST BE REPLACED WITH POWER LIMITED FIRE PROTECTIVE CABLE TERMINALS MARKING SHOWN IN CIRCLES ARE FOR McDONNELL amp MILLER L W C O THOSE NOT IN CIRCLES ARE FOR HYDROLEVEL SAFGARD STEAM PZ BOILER WITH 24V HONEYWELL INTERMITTENT IGNITION OPTIONAL VENT DAMPER AND ELECTRONIC L W C O BOILERS WITH INPUT OF 300 000 BTU HR OR GREATER WARNING BLOCKED VENT SAFETY SWITCH MUST BE MOUNTED TO DRAFT HOOD BEFORE OPERATING THE BOILER SEE INSTRUCTION MANUAL GG 40 BEFORE INSTALLING VENT DAMPER READ WARNING LABEL ON THIS BOILER AND VENT DAMPER READ SLANT FIN VENT DAMPER INSTALLATION INSTRUCTIONS FOR PROPANE USE S8600M OR 8670E FOR NATURAL GAS S8600F S8600M OR S8670E OPTIONAL VENT DAMPER SLANT FIN VENT DAMPER FLEX METALLIC 51 15 CONDUIT VENT DAMPER HARNESS SUPPLIED WITH VENT DAMPER 3444 RECEPTACLEA 1 z 3 RECEPTACLE B CONNECTS TO MALE PLUG ON ADAPTER HARNESS WHITE NEUTRAL C 5 ROLL OUT 120V 24V Rouen HOT BLK He RED S8600 OR 8670
44. Y 5 40 BEFORE INSTALLING VENT DAMPER REAO WARNING LABEL ON THIS BOILER AND VENT DAMPER READ SLANT FIN VENT DAMPER INSTALLATION LY FOR NATURAL GAS SB600F VENT DAMPER HARNESS SUPPLIED WITH VENT DAMPER RECEPTACLE 8 CONNECTS TO MALE ON ADAPTI NEUTRAL WHITE 0 3 84 E THERMOSTAT 58600 GR 58670 PILOT LIGHTER ROLL OUT AND BLOCKED SLANT FIN VENT SHITCHES kukapi TERMINALS MARKING SHOWN FOR a BOILER HARNESS WIRE LEGEND m i6 m OG Mer made FACTORY SUPPLIED 399i 1O Os EKNECTORS 280 FIELD CONNECTED PLUS RECEPTACLE PEON ATHE BISEONNECT MEANS amp OVERLOAD PROTECTION IF ANY OF 748 ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 105 C OR ITS EQUIVALENT IF THE RED CABLE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH POWER LIMITED FIRE PROTECTIVE 18 2 CABLE X PLUG amp RECEPTACLE ARE IN COMBINATION CONTROL BOX ON SENTRY SERIES BOILERS SENTRY BOILERS ONLY IF THE WIRES MARKED MUST BE REPLACED IT MUST BE REPLACED WITH POWER LIMITED FIRE ITECTIVE CABLE GALAXY SENTRY 41 1196 D 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 BOILERS UNDER 300 000 BTU HR INPUT WARNING BLOCKED VENT SAFETY SWITCH MUST BE MOUNTED TO
45. adder for the vent damper used If room thermostat has not been adjusted connect entire system to thermostat and run the system while measuring the current drawn through the thermostat wires Set the heat anticipator at the value of current measured For more information see Slant Fin vent damper installation manual pub VD 40 and the manufac turer s vent damper booklet shipped with the vent damper OPERATING INSTRUCTIONS BASIC Before firing boiler make these checks 1 Relief valve is installed Installation of the relief valve shall be consistent with the ANSI ASME Boiler Pressure Vessel Code Valve opening is NOT closed or reduced in size 2 Draft hood is installed and vented to chimney 3 All wiring is completed following applicable wiring diagrams 4 f a vent damper is added damper is in full open posi tion See instructions furnished with vent damper 5 Using soap solution check for gas leaks in all gas piping from meter to boiler pilot and manifold DO NOT use open flame FILLING AND VENTING WATER SYSTEMS A Fill the system with water Vent or purge off air B Fire the boiler as soon as possible see following warning and instructions and bring water temperature to at least 180 degrees while circulating water in the system C Vent air and add water as needed to achieve operating pressure on boiler gauge Pressure must be between approximately 12 psi cold water and 25 psi at water temperature setting of high
46. amper device and indicates the proper vent damper model number This device cannot be used with millivolt ignition system or boilers with input of 300 000 Btu hr or greater equipped with continuous pilot Il A INSTALLATION INSTRUCTIONS BEFORE YOU START TO INSTALL 1 Read this installation manual the DANGER plate attached to the top of the boiler the WARNING on the wiring diagrams vent damper carton and operator cover 2 Perform pre installation inspection as required by ANSI specification 221 66 3 Turn off all electrical power gas supply and wait for sys tem to cool for previously installed boilers 4 Select a proper convenient location see figures 4 and 5 5 Carefully unpack the unit DO NOT FORCE IT OPEN OR CLOSED Forcing the damper may damage the gear train and void the warranty WARNING DANGER Once you have begun vent damper installation procedure DO NOT restore electric power and gas supply until installation and inspection have been completed in order to prevent the main burners from operating DO NOT operate the boiler until the vent damper harness RECEPTACLE is plugged into MALE PLUG as described in the installation instructions and the vent damper installation and checkout procedures have been completed Failure to observe this warning may create a haz ardous condition that could cause an explosion or carbon monoxide poisoning B 1 This device must be installed after the appliance draft ho
47. at the free end of the metallic conduit fasten to jacket b Connect RECEPTACLE B free end of vent damper harness into MALE PLUG see correct wiring dia gram for both continuous and intermittent pilots 5 All Slant Fin Corp Galaxy steam boilers equipped with intermittent pilot ignition and continuous standing pilot systems are factory wired except for the wires to the low water cut off and pressure cut off Wire these controls with wire provided with boiler see boiler wiring diagram on boil er Then follow previous instructions shown in 4 above 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 D AFTER INSTALLATION 1 Operate system through two complete cycles to check for opening and closing in proper sequence and proper burn er operation DAMPER MUST BE IN OPEN POSITION WHEN BOILER MAIN BURNERS ARE OPERATING 2 Perform installation checks as required by ANSI specifica tion 221 66 3 Replace the front cover of the boiler 4 Check the troubleshooting section if problems arise with the installation E THERMOSTAT HEAT ANTICIPATOR ADJUSTMENTS If the 24V room thermostat that controls this boiler has an adjustable heat anticipator and has previously been adjusted without a vent damper then see publication VD 40 for correct electrical requirement
48. bsence of such requirements to the National Fuel Gas Code ANSI Z223 1 latest edition This installation must also conform to the additional require ments in this Slant Fin instruction book Installation and service to be performed by a qualified installer service agency or the gas supplier NATURAL GAS FIRED BOILER LOCATION Provide a level solid foundation for the boiler Location should be as near the chimney as possible so that the flue pipe from boiler to chimney is short and direct Automatic gas ignition system components shall be installed so these components will not be subjected to dripping water during installation or service WARNING LIQUEFIED PETROLEUM L P PROPANE GAS FIRED BOILER LOCATION REQUIRES SPECIAL ATTENTION Liquefied Petroleum LP propane gas is heavier than air Therefore propane boilers piping valves should NOT be installed in locations where propane leaking from defective equipment and piping will pool in a basement or other space below the leak A spark or flame from the boiler or other source may ignite the accumulated propane gas causing an explosion or fire Provide a level solid foundation for the boiler Location should be as near the chimney as possible so that the flue pipe from boiler to chimney is short and direct THE UNIFORM MECHANICAL CODE may be in effect in your geographic area The following precautions are cited by the 1994 UNIFORM MECHANICAL CODE section 304 6 LPG A
49. cessibility clearance of 24 on sides requiring ser vicing and 18 on sides used for passage C All minimum clearances shown above must be met This may result in increased values of some minimum clearances in order to maintain the minimum clearances of others D Clearance from steam and hot water pipes shall be 1 At points where hot water or steam pipes emerge from a floor wall or ceil ing the clearance at the opening through the finished floor boards or wall or ceiling boards may be not less than 1 2 Each such opening shall be covered with a plate of noncombustible material SAFETY KEEP THE BOILER AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS VENT PIPING A Vent piping installation must be in accordance with ANSI Z223 1 latest edition National Fuel Gas Code Part 7 Venting of Equipment Other local codes may also apply and must be followed B Boiler vent pipe must be the full diameter of the boiler draft hood outlet See dimensions page 2 If a vent damper is added its diameter must be equal to the hood outlet and must be located past the hood outlet See installation instructions furnished with vent damper and in the section Vent Damper Installation of this instruction book C If more than one appliance vents into a common breeching the area of the breeching must be equal to the area of the largest vent plus 50 of the area of the additional vent
50. d near the end of the steam supply main see figures 2 and 3 Main air vents should be located fifteen inches from the drip and if possible eight inches above the pipe so that water hammer does not damage the vent and render the vent inoperable For more information on air vents check with any manufac turer of steam accessories steam traps boiler feed pumps air vents etc 5 Process water applications involving steam boilers requires GALAXY Lx the use of heat exchangers Any process application that FIGURE 2 constantly uses fresh water into a steam boiler can and will cause scaling with deposits forming in the boiler and sur All fitting sizes same as figure 1 rounding piping This will damage the boiler 6 If valves are used on the supply side of the boiler the valve RDUM ii port opening must be the same size as the surrounding pipe Full flow type valves 7 Piping should provide a means of cleaning and flushing the Typical parallel flow heating system of the sediment for safe efficient operation 4 of RECOMMENDED PIPING FOR A ONE PIPE PARALLEL piping a low pressure steam boiler FLOW LOW PRESSURE STEAM HEATING SYSTEM WITH A WET OR DRY GRAVITY See Note No 3 CONDENSATE RETURN AND A HARTFORD LOOP See Note No 1 on page 6 FIGURE 1 Steam Supply HEADER 214 x 12 LONG MINIMUM q4 2 2 2 2 2 TEE 21 2 Supply 18 Minimum Height 212x112x112 TEE 7 Close Nipple
51. e building When buildings are insulated caulked and weather stripped now or later on direct opening to outside may be required and should be provided If the boiler is not on an outside wall air may be ducted to it from outside wall openings Air Eliminating System FLOW CONTROL VALVE IF USED w SUPPLY FLOW CONTROL VALVE IF USED w ALTERNATE PUMP LOCATION DIAPHRAGM AUTOMATIC COMPRESSION 3 4 RELIEF VALVE WATER f EED AND PRESSURE REDUCING VALVE BY OTHERS ALTERNATE gt WATER FEEDAND gt PRESSURE REDUCING VALVE BY OTHERS WATER FEED AND PRESSURE REDUCING VALVE BY OTHERS H PRESSURE LIMIT ta O D TUBE CUT TO SIZE AT PRESSURE GAUGE NIPPLE COMP ADAP FITT WATER LEVEL 25 2 OFF FLOOR TEE MALE PIPE 4 x ADAPTER TO O D NIPPLE A x 5 TH AT BOTH ENDS NIPPLE TEE 8 LOW WATER CUT OFF DRAIN PIPE SUPPLY 5 The National Fuel Gas Code ANSI Z223 1 latest edition speci fies openings for air under various conditions Local codes may specify minimum opening sizes and locations The following recommendation applies to buildings of energy saving construc tion fully caulked and weather stripped Provide one GRILLED opening near the floor and one near the ceiling on an outside wall near the boiler or duct from such openings to the boiler EACH opening to be a minimum of one square inch per 2000 Btuh input to ALL APPLIANCES in the ar
52. ea For a total appliance input of 200 000 Btuh each open ing will be 100 square inches A grilled opening 10 x 10 has 100 square inches of area If fly screen must be used over openings double the area and inspect and clean the screen frequently Openings must NEVER be reduced or closed If doors or win dows are used for air supply they must be locked open Protect against closure of openings by snow and debris Inspect frequently NO MECHANICAL DRAFT EXHAUST OR SUPPLY FANS ARE TO BE USED IN OR NEAR THE BOILER AREA The flow of combustion and ventilating air to the boiler must NOT be obstructed DRAFT HOOD The draft hood supplied is part of the listed boiler assembly DO NOT alter the hood See dimensions page 2 DIRECT HOT WATER LINE TO WASHING MACHINES SUPPLY TEMPERED HOT WATERN TO FIXTURES TEMPERING PUMP VALVEN AUTOMATIC LOCATION WATER TANKLESS HEATER COMBINATION DIAPHRAGM COMPRESSION TANK FILL VALVE AND PRESSURE REDUCING VALVE BY OTHERS Pa FLOW CONTROL VALVE Size to tankless coil capacit Y Toran NOTE install tempering valve below cold water inlet to heater SPECIAL FLUSHING INSTRUCTIONS Installation of new boiler may break loose a heavy accumulation of sediment and scale from old piping and radiators It is extremely important to blow down your McDonnell Cut off 67 more frequently the first week First week 3 times Thereafter at least once a week Exce
53. ecomes Btuh Input cu ft metered in 3 minutes x 1000 Btu cu ft x 20 Example 2 For 1050 Btu cu ft gas this becomes Btuh Input cu ft metered in 3 minutes x 1050 Btu cu ft x 20 4 The higher heating value of gas varies substantially for different localities Consult with Slant Fin s Technical Service Dept for re orificing procedures if any of the fol lowing apply a Boiler burner is overfiring CAUTION National Fuel Gas Code ANSI Z223 1 latest edition 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 b Poor higher heating value of gas is causing the actu al input to be substantially lower than the rating plate indication Higher heating value of gas is commonly known as heating value GAS RATE TABLE The gas metered in 3 minutes to obtain rated input for each boiler model using 1000 Btu cu ft gas is tabulated in gas rate table Boiler rated input in cu ft hr of 1000 Btu cu ft Natural Gas Cubic Feet Gas Consumption 1000 Btu cu ft gas in 3 min utes at rated output GALAXY B Main Burner 1 Fire the boiler continuously for at least 15 minutes to reach burner operating temperature 2 Observe the flames all burners The base of all flame jets should be blue The tips should be blue shading to orange NOTE Dust disturbed by any movement
54. egular loss of water from water boiler system may indi cate either a system leak or a faulty air control system or a faulty automatic fill valve IIl ANNUAL INSPECTION AND CLEANING A It is important that this boiler be inspected by a competent serviceperson to help insure safe and reliable operation B Check for gas leaks from valve and gas piping to burners and pilot If leaks are found repair or replace as required C This inspection should include 1 Controls check See SAFETY CHECK IV on page 16 2 Recheck of input gas rate to burners See Initial Start paragraph in Operating Instructions section 3 Re adjusting for best flame characteristics of main flame and pilot s See Initial Start paragraph in Operating Instructions section and see Burner Adjustment section 4 Burner and boiler flue passage cleanliness BURNER AND FLUE CLEANING see sketch It is suggested that paper be placed on burners to collect any foreign material in cleaning flues 5 Remove draft hood jacket top and flue cover 6 Use wire brush to clean flueways 7 Replace flue cover and re seal with furnace cement Replace jacket top and draft hood and reconnect to smoke pipe using screws Remove and dispose of paper and accumulated material 8 If burner surfaces are not clean or if uneven flame indi cates plugged burner ports remove and clean burners NOTE TO REMOVE BURNERS a Remove holding wire clip at orifice b Disconnect
55. eights NJ 07922 Consult glycol manufacturers for sources of propy lene glycol B Water Treatment A good water treatment program will not only extend the useful life of this boiler but it will also save much of the time and expense of repairs made necessary by pre ventable occurrences A reputable water treatment company should be consulted to evaluate and determine the best overall treatment pro gram for your boiler equipment VI KEEP THE BOILER AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS GALAXY 17 SEQUENCE OF OPERATION FOR GALAXY BOILERS EQUIPPED WITH CONTINUOUS BURNING PILOT FOR DIAGRAMS SHOWN ON PAGE 18 21 LIGHTED PILOT HEATS THERMOCOUPLE AND KEEPS PILOTSTAT OPEN THERMOSTAT CALLS LOW LIMIT FOR TANKLESS COIL FOR HEAT OR CALLS FOR HOT WATER gt Y WATER BOILERS EQUIPPED WITH COMBINATION AQUASTATS HIGH LIMIT CONTACTS CLOSED NO NO FURTHER CIRCULATOR ENERGIZES LOW WATER CUT OFF WHEN USED CONTACTS CLOSED ACTION UNLESS LOW LIMIT L8124 ONLY PRESSURE CUT OUT WHEN USED CONTACTS CLOSED IS CALLING FOR HOT WATER Y YES VENT DAMPER VENT DAMPER RELAY ENERGIZED MODELS UNDER VENT DAMPER MOTOR MOVES OPEN VENT DAMPER OPENS 300 000 BTU HR END SWITCH CLOSES Y MAIN VALVE OPERATOR OPENS LIT PILOT IGNITES MAIN BURNERS IF PILOT SHOUL
56. eplace all buried wet return lines 3 All equipment air vents radiation equipment etc in the steam heating system should be checked for proper opera tion All piping should be checked for proper pitch 4 It is good engineering practice to repack or tighten the pack ing nuts on all valves in the heating system BLOWING OFF A LOW PRESSURE STEAM BOILER 1 MODELS THAT HAVE NO TANKLESS HEATER OR NO PROVISION FOR HEATER A Those models without tankless heaters or provision for tankless heaters have a skimmer giving the advantages of a surface blow pipe that has been built into the casting to insure rapid skimming of oil and grease through a 3 4 tapping located on the right hand jacket side panel 8 9 16 from the top and 13 1 4 from the front of the boil er see Figure A B Turn off electrical power supply to boiler Allow boiler to cool down and steam pressure to reduce to zero before removing skimmer tapping plug Check for steam pressure by testing the pop safety valve Keep your hands and all parts of your body away from the discharge end of the safety valve Drain boiler down one to two inches below skimmer tapping There will be water in the skimmer trough The water might be hot Remove skimmer plug slowly and carefully Install 3 4 skimmer valve elbow and length of pipe and place a bucket underneath the open end of the pipe Cover bucket with a piece of cloth C Fill boiler slowly until water level is two inc
57. g chimney may require cleaning D Chimney or vent must extend at least 3 feet above its pas sage through a roof and at least 2 feet above any ridge with in 10 feet of the chimney MINIMUM CLEARANCES FROM COMBUSTIBLE CON STRUCTION A Minimum boiler clearances shall be as follows GALAXY GG SERIES MODELS GG 75H MODELS GG 250 THROUGH GG 225H THROUGH GG 399H MINIMUM CLEARANCE MINIMUM CLEARANCE FOR COMBUSTIBLE FOR COMBUSTIBLE CONSTRUCTION CONSTRUCTION MINIMUM CLOSET MINIMUM ALCOVE CLEARANCE CLEARANCE Front Front Rear Rear 6 Alcove Left Side Left Side 6 Right Side Right Side 6 Top Top 36 Flue Connector Flue Connector 6 Type B Vent Type B Vent 1 4 GAS PIPING GALAXY GX A Local installation codes apply The pipe joint compound used GXH SERIES GXHA SERIES MODELS GXH 105 THROUGH GXH 190 MODELS GXH 210 TO GXH 300H GX 225 TO MODELS GXHA 100 GXHA 120 GXHA 160 MINIMUM CLEARANCE GX 250 FOR COMBUSTIBLE CONSTRUCTION MINIMUM CLOSET CLEARANCE amp GXHA 200 FOR COMBUSTIBLE CONSTRUCTION MINIMUM ALCOVE CLOSET AND ALCOVE CLEARANCE CLEARANCE Front Front Alcove Front Rear Rear 6 Rear Left Side Left Side Left Side Right Side Right Side Right Side Top Top Top Flue Connector Flue Connector Flue Connector Type Vent Type Vent Type B Vent FOR COMBUSTIBLE CONSTRUCTION B Provide ac
58. height is H as shown in fig ures 2 and 3 The minimum height of H must be at least equal to the sum of the pressure drop of the system plus three times the friction loss of the wet return but not less than 18 for a sys tem with a 1 8 psi steam pressure drop and not less than 28 for a system with a 1 2 psi steam pressure drop 3 Modern steam boilers are smaller in water content than the boilers that they replace therefore a mechanical return sys tem pump receiver etc must be employed if conditions exist such that uniform condensate return flow to the boiler cannot be maintained Pocketing of condensate and the inability to maintain the correct minimum height between the steam supply main and the water level in the boiler are but a few of the many condi tions that indicate the use of a mechanical return system Any use of a receiver and pump must be coordinated with the makeup water and controlled by the boiler water level control on the boiler This description is typical of a boiler feed pump as opposed to a condensate pump that pumps condensate regardless of the water level in the boiler 4 In any steam system one of the requirements is the removal of air from the system A mechanical return system in most cases has an air vent on the receiver A gravity return sys tem 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 an
59. hes from top of gauge glass This is the starting water level for skimming FIGURE A Right side view of Galaxy models that are NOT equipped with or DO NOT have provisions for tankless heaters l 13 14 POP SAFETY VALVE 2 4 SUPPLY DRAFT START OF SKIMMING LEVEL 2 BELOW TOP OF GAUGE GLASS SEE 1 ABOVE GAUGE GLASS 3 4 SKIMMER DRAIN VALVE 90 2512 NORMAL COVERED BUCKET OPERATING WATER LEVEL GALAXY only Fire boiler to produce steam If the system is heavily laden with oil it may be difficult to obtain much more than a pound or so of pressure Set the pressure control at about 7 psi The higher the steam pressure you can use the better and faster the cleaning D As a steam develops open the SKIMMER drain valve with caution to skim the oil and film from the top of the water DO NOT open the boiler drain valve Close the skimmer drain valve when the water level drops to about 5 from the top of the gauge glass The water may stop before the level drops to 5 below the top of the glass Refill boiler until water level is again two inches from the top of the gauge glass E Repeat D above until all film is skimmed off and the water settles to a desired normal movement Add makeup fresh water to the boiler as described in D above during the blow off operation to maintain the proper skimming water level in the vessel Empty bucket frequently in order to see the difference in water cleanl
60. il 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 skim ming 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 Repeat this process until all film is skimmed off lower the water level to 25 1 2 from the bottom of the boiler see Figure B When all surging has stopped turn off the boil er remove skimmer valve and plug the tee Check the pop safety valve for proper operation E The entire process may have to be repeated over a period of a few days on extremely fouled systems 3 CLEANING PIPING SYSTEM A To clean piping system open all valves at the heating ele ments after getting up a good head of steam shut the boiler down and allow the condensate to return to the boil er The condensate will carry the oil film with it Again blow off the boiler On extremely fouled systems it may require several visits over a period of a few days to clean the system B When steam only no water is released through the hand valve the boiler will not surge or flood CARE AND MAINTENANCE WARNING THE FLOW OF COMBUSTION AND VENTILAT ING AIR TO THE BOILER SHOULD NOT BE OBSTRUCTED This section must be brought to the attention of the owner by the installer so that the owner can
61. iness F When surging has stopped and water is clean and no film can be seen floating in the bucket shut off boiler drain down to level of skimmer tapping remove valve plug skimmer tapping and refill the boiler to the normal operat ing water 25 1 2 from the bottom of the boiler see Figure A below Check the pop safety valve for proper operation G The entire process may have to be repeated over a period of a few days on extremely fouled systems 2 MODELS WITH TANKLESS HEATER OR WITH TANKLESS HEATER PLATES ONLY A Turn off electrical power supply to boiler Allow boiler to cool down and allow pressure to reduce to zero before attempting removal of components Check for steam pres sure by testing safety valve Keep your hands and body away from the discharge end of the valve Remove 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 B 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 FIGURE B Left side view of Galaxy models that are equipped with or have provisions for tankless heaters REMOVE POP SAFETY REPLACE IN TEE SEE INSTRUCTIONS SUPPLY DRAFT HOOD SKIMMING WATER LEVEL COVERED BUCKET GALAXY C Open the SKIMMER valve with caution DO NOT open the boiler drain valve Fill the boiler slowly unt
62. ior 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 CONTINUOUS PILOT VENT DAMPER AND MM 67 L W C 0 10 LIMIT IF WITH TANKLESS BOILERS UNDER 300 000 BTU HR INPUT WARNING BLOCKED VENT SAFETY SWITCH MUST BE MOUNTED TO DRAFT HOOD BEFORE OPERATING THE BOILER SEE INSTRUCTION MANUAL GG 40 BEFORE INSTALLING VENT DAMPER READ WARNING LABEL ON THIS BOILER AND VENT DAMPER READ SLANT FIN VENT DAMPER INSTALLATION INSTRUCTIONS STEAM PZ BOILER WITH CONTINUOUS PLOT VENT DAMPER AND ELECTRONIC L W C O BOILERS UNDER 300 000 BTU HR INPUT WARNING BLOCKED VENT SAFETY SWITCH MUST BE MOUNTED TO DRAFT HOOD BEFORE OPERATING THE BOILER SEE INSTRUCTION MANUAL GG 40 BEFORE INSTALLING VENT DAMPER READ WARNING LABEL ON THIS BOILER AND VENT DAMPER READ SLANT FIN VENT DAMPER INSTALLATION INSTRUCTIONS SLANT FIN VENT DAER 4 3 FLEX METALLIC CONDUIT FLEX METALLIC CONDUIT VENT DAMPER HARNESS SUPPLIED MITH VENT DAMPER RECEPTACLE B CONNECTS TO ADAPTER VENT DAMPER HARNESS SUPPLIED WITH VENT DAMPER TBAHM RECEPTACLE B CONNECTS TO MALE PLUG ON ADAPTER HARNESS MALE PLUG E MONIA ROLL OUT lt SWITCH RED N WHITE NEUTRAL pd 1
63. ither of these devices shut down the burners follow instructions in the section To Turn Off Gas To Appliance and call your service technician or gas supplier LOW WATER CUT OFF CHECK OUT A Electronic Probe Type Low Water Cut off If this boiler is fac tory equipped with an electronic probe type low water cut off operation of cut off should be checked at least twice a year as follows 1 While boiler is running drain down boiler water slowly through boiler drain cock shown on page 7 just until light goes on Boiler should shut down 90 seconds after light goes on 2 Be sure that it is the low water cut off and not the room thermostat pressure cut out energy cut off or other con trol that has shut off the burner 3 Refill the boiler and repeat test 4 Refill the boiler and reset controls for normal operation B Float type low water cut off If this boiler is factory equipped with a McDonnell amp Miller float type low water cut off the low water cut off must be blown down flushed at least once a week 1 CAUTION When flushing float type low water cut off control hot water and steam will flow out the blow down valve Blow down valve is illustrated on page 5 SPECIAL FLUSHING INSTRUCTIONS Installation of new boiler may break loose a heavy accu mulation of sediment and scale from old piping and radia tors It is extremely important to blow down your McDonnell cut off more frequently the first week First week
64. kwise to 13 Replace control access panel Galaxy models only Turn on all electric power to the appliance 15 Set thermostat to desired settings To Turn Off Gas To Appliance Set the thermostat to lowest setting Turn off all electric power to the appliance if service is to be performed Remove control access panel Galaxy models only Turn gas control knob clockwise to OFF DO NOT force Replace control access panel Galaxy models only FIGURE 13 Electric ignition Pilot in Boiler Side View Gas Valve No VR8204 or VR8304 Aluminum Pilot Gas Tube 2 INTERMITTENT PILOT IID SYSTEM FOR BOILERS EQUIPPED WITH HONEYWELL GAS VALVE VR8204 AND VR8304 see figures 13 and 14 SAFETY INFORMATION FOR YOUR SAFETY READ BEFORE OPERATING 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 B This appliance is equipped with an ignition device which automatically lights the pilot DO NOT try to light the pilot by hand BEFORE OPERATING smell all around the appliance area WON 11 for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS DO NOT try to light any appliance DO NOT touch any electric switch DO NOT use any phone in your building Immediately call yo
65. make the necessary arrangements with a qualified service agency for the periodic care and maintenance of this boiler The installer must inform the owner that the gas supplier can recommend a number of qualified service agencies The installer must also inform the owner that the lack of proper care and maintenance of this boiler and any fuel burning equipment may result in a haz ardous condition I GENERAL MAINTENANCE Refer also to User s Information Manual These operations are recommended to be performed at reg ular intervals A BOILER HEATING SURFACES clean off all coatings found B BOILER CONTROLS check contacts settings correct functioning C PIPING check piping and accessories for leaks D CHIMNEY and BREECHING check for obstructions and leaks E BOILER ROOM AIR SUPPLY check air vents for contin ued POSITIVE supply of air as required Air needs are greatest in cold weather Air vents must be open and free of obstruction F WATER SYSTEM check 1 System to be full of water and pressure to remain sta ble at correct setting on gauge 2 Air control system noise and air binding in radiation should not occur 3 Water lines slightest leaks should be corrected 4 Low water cut off for operation see instructions fur nished with unit 15 Il WATER LEVEL CHECK DURING HEATING SEASON A Check water level regularly and add water slowly to sys tem when needed If much water is added venting may be necessary B R
66. mostat to lowest setting Turn off all electric power to the appliance Remove control access panel Galaxy models only Turn gas control knob clockwise to OFF Wait five 5 minutes longer for propane to clear out any gas then smell for gas including near the floor If you then smell gas STOP Follow B in the safety information above If you don t smell gas go to next step Q N FIGURE 12 Valve VR8200 and VR8300 GAS CONTROL KNOB i SHOWN IN OFF RED BUTTON POSITION GALAXY 7 8 10 11 12 14 _ 5 Remove the pilot access panel located below and behind the gas control unit Find pilot follow metal tube from gas control The pilot is between two burner tubes CERE behind the pilot access panel Turn knob on gas control counterclockwise to PILOT Push in red button all the way and hold in Immediately light the pilot with a match Continue to hold the red button in for about one 1 minute after the pilot is lit Release but ton and it will pop back up Pilot should remain lit If it goes out repeat steps 5 through 10 f knob does not pop up when released stop and immedi ately call your service technician or gas supplier e f the pilot will not stay lit after several tries turn the gas control knob to OFF and call your service technician or gas supplier Replace pilot access panel Turn gas control knob countercloc
67. n 1V2 Cross 3 14 Nipple 1 Manual fill water supply 112 Union Hot water fill is preferable but not required For auto feeding see manu emt x facturer s technical instructions 1 Plug FIGURE 3 11 2x3 4 Bushing Return Counter Flow One Pipe Low Pressure Steam Piping Manual fill water supply Steam Supply to Radiation Equipment T AHartford Loop is recommended for low pressure steam systems with gravity condensate returns Pipe sizes shown above for Hartford Loop are recommended by Slant Fin However certain local codes may require larger pipe sizes Consult with local authorities A The equalizer should be full size from the steam supply to the operating water level Hot water fill is preferable For auto feedings see manufacturer s tech nical instructions Counter flow piping is sized one pipe size larger than a parallel flow piping This allows steam to travel in one direction while the condensate travels in the other direction This along with a steeper pitch is a must for safe effi cient operation 8 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 d
68. nting system 7 Adjust gas input to that shown on boiler rating plate CONDENSATION IN BOILER FLUES OR IN VENT SYSTEM CAUSE REMEDY 1 Underfiring 1 Increase firing rate to that shown on rating plate 2 Boiler water maintained at too low a temperature level 2 Set low limit controls to maintain a higher water tempera 3 Long horizontal run of smokepipe ture If boiler is not equipped with low limit replace with 4 Inadequate chimney or venting system one which has a combination low limit high limit aquastat 3 Relocate boiler or insulate breeching 4 Check chimney and venting recommendations 28 GALAXY PIPING A HEATING COOLING SYSTEM TO A WATER BOILER AND CHILLER Figure below illustrates a method of piping a heating cooling system to a water boiler and a chiller Hand valves shown or automatic valves must be installed to prevent circulation of chilled water in the boiler or hot water in the chiller BOILER The air control system and pressure control system must oper ate with chiller only or the boiler only being valved to the piping system Separate control devices on the boiler and chiller may be used or a single set of air and pressure controls on the common piping may be preferred If the boiler is used to supply hot water to heating coils in air handling units flow control valves or other devices must be installed to prevent gravity circulation of water in the coils dur ing the cooling cycle IF R
69. od between the draft hood outlet and the connector to the outdoor chimney or vent as close to the draft hood as practicable and without modification of the draft hood or the damper See figures 4 and 5 2 The inlet size of the vent damper must be the same nominal trade size as the outlet of the draft hood 3 This device must be located in a venting system or sec tion of a venting system so that it serves only the single appliance for which it is installed See fig 9 4 Clearances of not less than 6 inches 152mm must be maintained from combustible materials with provisions for access for service 5 steam boilers are equipped with integral draft diverter consists of front section factory assembled to the boiler and the rear section shipped with the boiler The rear section must be assembled to the boiler using three sheet metal screws see figure 7 Vent damper may be installed vertical or horizontal see figure 8a amp 8b C NOW PROCEED AS FOLLOWS 1 Remove the front cover of the boiler exposing the wiring compartment With all electrical power to boiler off locate MALE PLUG if boiler has an input of 300 000 Btu hr or greater locate Receptacle A see wiring diagram attached to boiler a copy of this may also be found in this manual To find the correct wiring diagram in this manual match the number found in the lower GALAXY FIGURE 4 INSTALL HERE VENT DAMPER EXTERNAL DRAFT HOOD WRONG L
70. oes not apply to NATURAL gas fired boilers 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 Boiler Model Number Boiler Serial Number Installation Date PUBLICATION GG 40 Rev 2 BOILER DIMENSIONS Vent Damper Electrical Pressure vent Safely ha and Vent Damper Relief Switch F Draft Knockouts Valve Hood epar Y Vent or Hi Limit I Control Supply I 0 Temperature ontrol Boilers Gas Valve 9 Gauge Alternate Retum D TQ Heater GG 75 thru Rollout Tappings ta Sale GXH PT
71. our 4 Use table below to select proper pipe size Example Boiler model GG 300 is to be installed Distance from gas meter to the boiler is 50 ft Heating value of natural gas is 1020 BTU cu ft Select proper pipe size Gas flow 300 000 BTU hour 294 ft per hour 1020 BTU cu ft At 50 ft length of pipe match required capacity from table below choose higher capacity in this case is 440 cu ft per hour Required pipe size is 1 1 4 Improper gas pipe sizing will result in pilot flame outages insufficient heat and other installation difficulties For more information and also if other appliances are to be attached to the piping system see Appendix C of National Fuel Gas Code ANSI Z223 1 latest edition The boiler and its gas connection must be leak tested before placing the boiler in operation Use liquid soap solution for all gas leak testing DO NOT use open flame This boiler and its individual shut off valve must be discon nected from the gas supply piping system during any pres sure testing of that system at test pressures in excess of 1 2 PSIG This boiler must be isolated from the gas supply piping sys tem by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 PSIG All gas piping used should be inspected thoroughly for cleanliness before makeup A sediment trap must be provid ed as illustrated on
72. page 2 The minimum and maximum gas supply pressure at the inlet of gas valve are shown on the boiler rating plate for the type of gas used Gas supply pressure should never be less than minimum or more than maximum pressure when the boiler or any other appliance is turned on or off Length Gas Flow In Piping cu ft per hr i a Iron Pipe Size IPS inches 1 1 4 1 12 GALAXY 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 18 25 Other control systems may be factory supplied see User s Information Manual and Instructions packed with control system supplied D After placing the boiler in operation the safety shut off device must be tested See page 13 safety check BOILER ROOM AIR SUPPLY AND VENTILATION An ample supply of air is required to obtain combustion and ventilation Room temperature over 100 F may cause nuisance tripping of the Blocked Vent Safety Switch ALL AIR MUST COME FROM OUTSIDE directly through wall openings to the boiler or through unsealed openings around windows doors etc in the whol
73. ppliances Liquefied petroleum gas burning appliances shall not be installed in a pit basement or similar location where heavier than air gas might collect Appliances so fueled shall not be installed in an above grade under floor space or basement unless such loca tion is provided with an approved means for removal of unburned gas Consult Chapter 5 of the 1994 UNIFORM MECHANICAL CODE for design criteria of the approved means for removal of unburned gas BOILER FOUNDATION A Provide a solid level foundation capable of supporting the weight of the boiler filled with water and extending at least 2 past the jacket on all sides See dimensions of boilers page 2 For installation on non combustible floors only C If boiler is to be located over buried conduit containing elec tric wires or telephone cables consult local codes or the National Board of Fire Underwriters for specific require ments The Combustible Floor Kit part number printed on the boiler rating plate is the only one to be used when installing on combustible floors The boiler must NOT be installed on carpeting DO NOT place boilers above floor area containing radiant tubing CHIMNEY REQUIREMENTS A Galaxy boilers may be vented into a masonry vitreous tile lined chimney or UL LISTED Type B Venting system NOT EXPOSED to the OUTDOORS below the roof line Venting and sizing of venting system must be in accordance with Part 7 Part
74. ption McDonnell Cut off 42 must be blown down daily See CARE AND MAINTENANCE for instructions 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 PIPING AT BOILER WATER PIPING I CIRCULATING SYSTEMS A Packaged water boilers are equipped with a water circulat ing pump mounted to return the water into the boiler For some installations the pump should be on the supply main See PUMP LOCATION below II AIR CONTROL SYSTEM A DIAPHRAGM TYPE COMPRESSION TANKS are used to control system pressure in an AIR ELIMINATING SYS TEM an automatic air vent is used to REMOVE air from the system water See illustration on page 5 If system pressure needs further control add an additional tank or install a larger capacity tank Locate the tank near the boiler as illustrated An automatic air vent should be installed in the top of the boiler See illustration on page 5 B PUMP LOCATION Locating low head pump s on return to boiler is acceptable for smaller boiler sizes in res idences of one or two stories The alternate pump loca tion shown in illustration on page 5 is required in large multi story building installations especially when high head pumps are used The compression tank must be at the boiler or between boiler and supply main pump s C On a hot water boiler in
75. stalled above radiation level the boiler must be provided with a low water cut off device at the time of installation by the installer Flow Control Valve When domestic hot water tankless heater is used a flow control valve should be installed in supply piping to heating sys tem as shown in illustration on page 5 INSTALLATION INSTRUCTIONS FOR GXH LOW PRESSURE STEAM BOILERS EQUIPPED WITH TANKLESS OR PROVISION FOR TANKLESS AND McDONNELL amp 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 Low water cut off control 2 Fittings 3 L W C O instruction sheet B 1 Pressure gauge 2 High pressure limit control 3 Water level gauge 4 Fittings 5 Instruction sheet and assembly drawing 6 Steam safety valve and 3 4 street coupling 7 Drain cock 8 Thermostat Assemble above components exactly as shown in steam con trols assembly Two 1 2 tappings are on right side of boiler for this assembly Two holes are pre punched in jackets For con venience start assembling in the following steps 1 Install 1 2 x 5 1 2 brass nipple onto tee of L W C O 2 Mount 1 2 x 5 1 2 brass nipple into lower boiler tapping by rotating low water cut off 3 Assemble 90 brass tubing to tee adapter and L W C O 4 Install 1 2 x 6 brass nipple and 1 2 x 5 8 adapter tee in upper boiler tapping 5 Install syphon high pres
76. sure limit and pressure gauge with GALAXY 1 4 brass fittings 6 Install water level gauge without glass and its fittings 7 Install water level glass and mark the glass 25 1 2 from the bottom of the steel boiler base for the water level The steel boiler base should not be confused with a combustible floor kit when making the 25 1 2 measurement 8 Drain cock will be installed in return tee at the lower right side of casting 9 Safety valve and 3 4 street coupling should be installed in 3 4 tapping on top of boiler PIPING A LOW PRESSURE STEAM BOILER Boilers must be piped with good engineering practice and must conform to the requirements of ANSI ASME Boiler and Pressure Vessel Code section IV and to the authority having jurisdiction NOTES 1 Slant Fin makes no recommendation nor does Slant Fin imply that One Pipe Parallel and Counterflow Gravity Condensate Return systems shown on page 7 are the pre ferred systems These systems are merely two examples of many possible systems Determination of the proper system is based upon the application and is therefore beyond the scope of this instruction 2 The 18 minimum height shown in figures 1 3 is the mini mum height between the top of the jacket of the boiler and the 2 1 2 x 12 header centerline in the supply piping from the boiler It must NOT be confused with the minimum height between the water level and the lowest return bend of the steam supply main This
77. ur gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire depart ment Use only your hand to push in or turn the gas control knob NEVER use tools If the knob will not push in or turn by hand DON T try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion DO NOT use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control System and any gas control which has been underwater Operating Instructions STOP Read the safety information 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 Remove control access panel Galaxy models only Turn gas control knob clockwise to OFF DO NOT force Wait five 5 minutes longer for propane to clear out any gas then smell for gas including near the floor If you then smell gas STOP Follow B in the safety information on this page If you don t smell gas go to next step Turn gas control knob counterclockwise to ON Replace control access panel Galaxy models only Turn on all electric power to the appliance Set thermostat
78. using the appropriate tables in Appendix G in the National Fuel Gas Code ANSI Z223 1 latest edition Slant Fin Corp 2006 r7 SLANT FIN CORPORATION Greenvale N Y 11548 Phone 516 484 2600 27 7 7 FAX 516 484 5921 Canada Slant Fin 1 Mississauga Ontario www slantfin com
79. ve if used opens properly when the pilot is burning normally and that safety shutdown occurs within 2 1 2 minutes after the pilot flame is extin guished Observe operation for at least one cycle under automatic control to be sure the system is func tioning normally b For proper operation the pilot should engulf the ther mocouple powerpile generator or flame sensor as shown below PILOT FLAME 3 8 TO 1 2 THERMOCOUPLE POWERPILE GENERATOR OR FLAME SENSOR c To adjust pilot turn pilot flow adjustment screw on valve clockwise or counterclockwise to give a steady flame enveloping 3 8 to 1 2 of the tip of the thermo couple generator or flame sensor Note that turning the pilot adjustment screw clockwise will decrease the pilot flame GALAXY d Check safety shutdown of gas valve by following proce dure outlined CARE AND MAINTENANCE section VIII CONTROLS SAFETY CHECK Check all safety controls not previously mentioned Also follow directions in CARE AND MAINTENANCE section paragraphs IV through VII 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 The rollout safety switch is a single use one time thermal fuse to prevent the boiler from operating if flue passages are blocked If e
80. yond the boiler cabinet on all sides CHIMNEY HEIGHT 15 ft minimum from draft hood skirt to top of chimney CHIMNEY INSIDE DIAMETER must be same as Dimen sion C or larger Larger diameter and or height may be required if two or more boilers or a boiler and another appliance are vented to a single chimney 29 234 LEN 26 A 1 1 28 94 14 2 94 1 28 9 Tankless Heater Gonnections L GX only 2 26 26 7 RIGHT SIDE GG GX H PT BOILER MODEL 29 23 1 1 2 9 2314 14 Tapping on Steam Boilers GAS Natural Propane 334 26 33 26 1 28 9 1 2 94 298 23A 29 23 Tankless Heater Connections L except GX H PZ RIGHT SIDE GX H PZ PZT PPZT 36 36 30 36 36 30 30 1 28 94 1 2 9 1 2 94 32 32 26 29 324 23 29 23 7 55 14 33 3 8 E LS FRONT VIEW RIGHT SIDE Orifice ORIFICE SIZES AT HIGH ALTITUDES INCLUDES 4 INPUT REDUCTION FOR EACH 1000 FEET ELEVATION FEET Size for Sea Level 5 000 6 000 7 000 Natural Propane Natural Propane Natural Propane Natural Gas Natural Propane For L P Propane gas consult factory GALAXY INSTALLATION REQUIREMENTS The installation must conform to the requirements of the author ity having jurisdiction or in the a
81. ywell S8600F or M or S8670E intermittent pilot system with main burners fir ing disconnect the ignition cable from the S8600F or M or S8670E IGNITOR BOX The gas valve should shut off the main burners If the gas valve fails to shut down main burners when the test in 1 or 2 is performed replace the gas valve C Check for gas leaks from valve and gas piping to burners and pilot If leaks are found repair or replace as required A Providing Protection from Freezing Anti freeze is sometimes used in hydronic heating sys tems to protect against freeze up in the event of power failure or control shutdown when the building is unoccu pied It should be recognized that unless the building is GALAXY kept above freezing temperature by some means the plumbing system is not protected Two types of anti freeze may be used ETHYLENE GLY COL used in automobiles has desirable properties but is toxic Its use may be prohibited when system water glycol solution is in contact with a potable water vessel as with a tankless heater PROPYLENE GLYCOL is used in the quick freeze food industry it is practically non toxic Its use may be permitted when tankless heaters are used When anti freeze must be used inhibited propylene glycol is recommended Useful information on the characteris tics mixing proportions etc of glycol in heating systems is given in Technical Topics No 2A available from the Hydronics Institute 34 Russo Place Berkeley H

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