GSA
User’s Information Manual
Gas-Fired Steam Boilers
Hazard definitions
Propane gas odorant
Propane boilers only — Your propane supplier
Hazards that will cause severe personal injury,
mixes an odorant with the propane to make its pres-
ence detectable. In some instances, the odorant can
fade and the gas may no longer have an odor.
death or substantial property damage.
Hazards that can cause severe personal injury,
death or substantial property damage.
•
Propane gas can accumulate at floor level. Smell near the floor
for the gas odorant or any unusual odor. If you suspect a leak,
do not attempt to light the pilot.
Hazards that will or can cause minor personal
injury or property damage.
•
Use caution when attempting to light the propane pilot. This
should be done by a qualified service technician, particularly if
pilot outages are common.
Special instructions on installation, operation or
maintenance that are important but not related to
personal injury or property damage.
•
•
Periodically check the odorant level of your gas.
Inspect boiler and system at least yearly to make sure all gas
piping is leak-tight.
Consult your propane supplier regarding installation of a gas
leak detector.There are some products on the market intended
for this purpose. Your supplier may be able to suggest an
appropriate device.
The Boiler manual is for use only by a qualified
heating installer/service technician. Refer only to
this User’s Information Manual for your reference.
Improper installation, adjustment, alteration,
service or maintenance can cause property
damage, personal injury (exposure to hazardous
materials) or loss of life. Installation and service
must be performed by a qualified installer, service
agency or the gas supplier (who must read and
follow the supplied instructions before installing,
servicing, or removing this boiler. This boiler
contains materials that have been identified as
carcinogenic, or possibly carcinogenic, to humans).
•
INSTALLER — Please take time to review this
User’s Information Manual with the boiler owner.
Explain all maintenance and service procedures
and the correct “Lighting Instructions”.
If the information in this manual is not followed exactly, a fire or
explosion may result, causing property damage, personal injury or
loss of life.
Do not store or use gasoline or other flammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical 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.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service
technician or the gas supplier.
Part Number 550-110-739/0703
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GSA
Gas-Fired Steam Boilers – User’s Information Manual
To locate Lighting Instructions:
Find your boiler model number on boiler nameplate (begins with GSA).Read the valve manufacturer’s model and
name on the boiler gas valve.Locate the correct“Lighting Instruction”using the table below.Use only the Instructions
applying to your boiler model and gas valve. If you are in doubt which to use, please contact your boiler installer/
technician for assistance.
GSA standing pilot
With gas valve:
Boiler models
Page
Honeywell VR8200 or VR8300
GSA-075 through GSA-250
GSA-075 through GSA-175
4
5
Robertshaw 7200
Maintain your boiler using this schedule:
Service technician
Owner maintenance
(covered in Boiler Manual — for use only by a
(see pages 6 – 8 for instructions)
qualified service technician)
❏
Inspect:
❏
Daily
• Check boiler area
• Reported problems
• Boiler area
• Check boiler pressure gauge
• Check air openings
• Air openings
• Flue gas vent system
• Pilot and main burner flames
• Piping
❏
Monthly
• Check boiler and system piping
• Check venting system
• Boiler heating surfaces
• Burners and base
• Check/operate boiler relief
valve
• Check pilot and main burner
flames
❏
❏
❏
Service:
• Gauge glass
❏
❏
Periodically
• Test low water cutoff
• Shut down procedure
Start-up:
• Perform start-up per manual
End of season
Check/test:
• Gas piping
• Boiler waterline
• Limit controls and cutoffs
• Boiler relief valve
❏
Review:
• Review with owner
Part Number 550-110-739/0703
3
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GSA
Gas-Fired Steam Boilers – User’s Information Manual
Lighting Instructions
GSA-075 through GSA-250
Gas valve — Honeywell VR8200/VR8300
FORYOUR SAFETY READ BEFORE LIGHTING
If you do not follow these instructions exactly, a fire or explosion may result caus-
ing property damage, personal injury or loss of life.
A. This appliance has a pilot, which must be
C. Use only your hand to push down the reset button or turn the gas control
knob. Never use tools. If the knob or reset button will not operate by hand,
don't try to repair it, call a qualified service technician. Force or attempted
repair may result in a fire or explosion.
lighted 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.See below.
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 under water.
WHAT TO DO IF YOU SMELL GAS
•
•
Do not try to light any appliance.
•
•
Immediately call your gas supplier from a neighbor’s phone.
Follow the gas supplier’s instructions.
Do not touch any electric switch; do not use any phone in
your building.
If you cannot reach your gas supplier, call the fire department.
LIGHTING INSTRUCTIONS
1. Stop! Read the safety information above on this label.
9. Remove access panel located above burners.
2. Set the thermostat to lowest setting.
10. Find pilot — follow metal tube from gas control.
The pilot is between two burners behind the
access panel.
3. When equipped with Effikal vent damper Model RVGP, place
service switch in Hold Damper Open position.
4. Turn off all electrical power to the appliance.
11. Turn gas control knob counterclockwise
to
PILOT.
5. When equipped with Johnson Controls vent damper Model
M35, manually rotate damper blade in direction of arrow to
Open position indicated on damper assembly.
12. Push in red reset button and hold. Immediately light the pilot
with a match. Continue to hold reset button in for about one
(1) minute after the pilot is lit.
6. Turn gas control knob clockwise
to OFF.
13. Release reset button. Pilot should remain lit. If pilot goes out,
repeat steps 6 through 13.
7. When equipped with vent damper, verify damper blade is in
full open position.
•
If reset button stays depressed after release, stop and
immediately call your service technician or gas supplier.
•
If the pilot will not stay lit after several tries, turn the gas control
knob clockwise
or gas supplier.
to OFF and call your service technician
14. Replace access panel.
15. Turn gas control knob counterclockwise
16. Turn on all electric power to the appliance.
to ON.
17. When equipped with Effikal vent damper, place service switch
in Automatic Operation position.
18. Set thermostat to desired setting.
19. Replace front panel.
8. Wait five (5) minutes to clear out any gas. Then smell for
gas, including near the floor.If you smell gas, STOP! Follow
"B" in the safety information above. If you don't smell gas,
go to the next step.
TOTURN OFF GASTOTHE APPLIANCE
1. Set the thermostat to lowest setting.
3. Remove front panel.
2. Turn off all electric power to the appliance if service is to be
performed.
4. Turn gas control knob clockwise
5. Replace front panel.
to OFF.
4
Part Number 550-110-739/0703
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GSA
Gas-Fired Steam Boilers – User’s Information Manual
Lighting Instructions
GSA-075 through GSA-175
Gas valve — Robertshaw 7200
FORYOUR SAFETY READ BEFORE LIGHTING
If you do not follow these instructions exactly, a fire or explosion may result caus-
ing property damage, personal injury or loss of life.
A. This appliance has a pilot, which must be
C. Use only your hand to push down the reset button or turn the gas control
knob. Never use tools. If the knob or reset button will not operate by hand,
don't try to repair it, call a qualified service technician. Force or attempted
repair may result in a fire or explosion.
lighted 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.See below.
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 under water.
WHAT TO DO IF YOU SMELL GAS
•
•
Do not try to light any appliance.
•
•
Immediately call your gas supplier from a neighbor’s phone.
Follow the gas supplier’s instructions.
Do not touch any electric switch; do not use any phone in
your building.
If you cannot reach your gas supplier, call the fire department.
LIGHTING INSTRUCTIONS
1. Stop! Read the safety information above on this label.
9. Remove access panel located above burners.
2. Set the thermostat to lowest setting.
10. Find pilot — follow metal tube from gas control.
The pilot is between two burners behind the
access panel.
3. When equipped with Effikal vent damper Model RVGP, place
service switch in Hold Damper Open position.
11. Move selector arm on gas control right
to SET position.
12. Hold selector arm in SET position and immediately light the
pilot with a match. Continue to hold selector arm to SET for
about one-half (1/2) minute after the pilot is lit.
4. Turn off all electrical power to the appliance.
5. When equipped with Johnson Controls vent damper Model
M35, manually rotate damper blade in direction of arrow to
Open position indicated on damper assembly.
6. Depress and move selector arm left
to OFF.
13. Release selector arm. If pilot does not remain lit, repeat steps
6 through 13.
7. When equipped with vent damper, verify damper blade is in
full open position.
•
If the pilot will not stay lit after several tries, move selector
arm left
supplier.
to OFF and call your service technician or gas
14. Replace access panel.
15. Turn selector arm left
to ON.
16. Turn on all electric power to the appliance.
17. When equipped with Effikal vent damper, place service
switch in Automatic Operation position.
18. Set thermostat to desired setting.
19. Replace front panel.
8. Wait five (5) minutes to clear out any gas. Then smell for
gas, including near the floor.If you smell gas, STOP! Follow
"B" in the safety information above. If you don't smell gas,
go to the next step.
TOTURN OFF GASTOTHE APPLIANCE
1. Set the thermostat to lowest setting.
3. Remove front panel.
2. Turn off all electric power to the appliance if service is to be
performed.
4. Depress and move selector arm left
5. Replace front panel.
to OFF.
Part Number 550-110-739/0703
5
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GSA
Gas-Fired Steam Boilers – User’s Information Manual
Maintenance procedures
The boiler should be inspected and started annually,
at the beginning of the heating season, only by a
The following information provides detailed
instructions for completing the maintenance items
listed in “Maintain your boiler using this schedule” on page 3. In
addition to this maintenance, the boiler must be serviced and started
up at the beginning of each heating season by a qualified service
technician.
qualified service technician. In addition, the maintenance and care
of the boiler designated on page 3 and explained on the following
pages must be performed to assure maximum boiler efficiency and
reliability.Failure to service and maintain the boiler and system could
result in equipment failure, causing possible severe personal injury,
death or substantial property damage.
See page 8 for“Troubleshooting”procedures for common problems.
Component information
Rollout thermal fuse element
Spill switch
The Rollout TFE is located above the
burners. It cuts off gas flow should flame
rollout occur.
The Spill switch is attached to the draft
diverter. It cuts off gas flow if the vent
system becomes blocked.
Do not attempt to place
boiler in operation if rollout
Do not attempt to place
boiler in operation if spill
thermal fuse element cuts off gas flow.
Immediately call a service technician.Failure
to do so can cause severe personal injury,
death or substantial property damage.
switch cuts off gas flow. Immediately call a
service technician. Failure to do so can
cause severe personal injury, death or
substantial property damage.
❏ Check daily
Boiler area
❏ Check monthly
Boiler and system piping
To prevent potential of severe personal injury, death
or substantiaW-T
1. Visually inspect for leaks around piping, relief valve and other
fittings. Immediately call a qualified service technician to repair
any leaks.
8201 W. Calumet Rd.
Milwaukee, WI 53223l property damage, eliminate all materials
Have leaks fixed at once by a qualified service
technician. Continual fresh makeup water will reduce
discussed below from the boiler vicinity. If found:
•
•
Remove products immediately from the area. If they have
been there for an extended period, call a qualified service
technician to inspect the boiler and vent system for possible
damage from acid corrosion.
If products cannot be removed, immediately call a qualified
service technician to install an outside combustion air source
for the boiler (if not already installed).
boiler life.Minerals can build up in sections, reducing heat transfer,
overheating cast iron, and causing section failure.
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Severe damage to boiler
and system components can occur, resulting in possible severe
personal injury, death or substantial property damage.
Venting system
1. Visually inspect all parts or the flue gas venting system for any
signs of blockage, leakage or joints or deterioration of the piping.
1. Combustible/flammable materials — Do not store combustible
materials, gasoline or any other flammable vapors or liquids
near the boiler.Remove immediately if found.
2. Check vent system operation:
2. Air contaminants — See listing of contaminants on page 2.
a. With boiler firing, hold a candle or match below lower edge
of draft diverter “skirt.”If flame does not blow out, but burns
undisturbed, the vent system is working properly. If flame
blows out or flickers severely, the vent system must be
checked for obstructions or other causes of improper
venting.
Pressure gauge
1. Make sure the pressure reading on the boiler pressure gauge
does not exceed 15 psig. Normal operation is usually less than
5 psig. At certain times the system may be under vacuum
conditions.
b. Verify the vent damper opens before burners ignite.
2. Contact a qualified service technician if problem persists.
3. Notify your qualified service technician at once if you find any
problem.
Failure to inspect the vent system as noted above
and have it repaired by a qualified service
technician can result in vent system failure, causing severe
personal injury or death.
Air openings
1. Verify that combustion and ventilation air openings to the boiler
room and/or building are open and unobstructed.
6
Part Number 550-110-739/0703
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GSA
Gas-Fired Steam Boilers – User’s Information Manual
❏ Check monthly
❏ Check monthly
Boiler relief valve
Main burner flame
1. After following the warning directions
below, if the relief valve weeps or will
not seat properly, replace the relief valve.
Before testing, make certain
discharge pipe is properly
connected to valve outlet and arranged to
contain and safely dispose of boiler
discharge. Wear gloves to protect your
hands from hot surfaces. Verify that
Proper main burner flame
(see right):
1. Yellow-orange streaks may
appear (caused by dust).
Improper main burner flame:
1. Overfired — Large flames.
2. Underfired — Small flames.
3. Lack of primary air —Yellow tipping on flames (sooting will
discharge piping is installed in accordance with this manual and
the instructions on the relief valve tag.Failure to comply will expose
operator and others to severe personal injury or death.
occur).
Safety relief valves should be reinspected AT LEAST
ONCE EVERY THREE YEARS, by a licensed
plumbing contractor or authorized inspection agency, to ensure that
the product has not been affected by corrosive water conditions
and to ensure that the valve and discharge line have not been altered
or tampered with illegally.Certain naturally occurring conditions may
corrode the valve or its components over time, rendering the valve
inoperative. Such conditions are not detectable unless the valve
and its components are physically removed and inspected. This
inspection must only be conducted by a plumbing contractor or
authorized inspection agency — not by the owner. Failure to
reinspect the boiler relief valve as directed could result in unsafe
pressure buildup, which can result in severe personal injury, death
or substantial property damage.
❏ Periodically
Test low water cutoff
Probe-type low water cutoff
(see right)
Check probe-type low water
cutoff for proper operation.
Check the setting of the boiler limit control.The
control should never be set with a pressure above
10 psig. Operating at a higher pressure can cause damage to the
boiler relief valve.
1. Turn off power to boiler and
wait 5 minutes.
2. Drain water to bottom of
gauge glass.
The boiler relief valve must be tested at least
monthly during the heating season to verify the valve
3. Turn on power.
and discharge piping flow freely. If corrosion and/or deposits are
noticed within the valve body, testing must be performed more often.
A “try lever test” must also be performed at the end of any non-
service period. Follow the instructions below for a “try lever test”.
4. Set thermostat to call for
heat. Red neon lamp on
lower water cutoff should light.
5. Wait 5 minutes.Boiler should not fire.
6. Refill boiler to correct water line. Red lamp should go off.
7. Wait 5 minutes.Boiler should fire.
•
With the system at operating pressure, lift and hold the test
lever fully open for at least 5 seconds to flush the valve seat
free of sediment and debris.Then release lever and permit the
valve to snap shut.
8. Return thermostat to normal setting.
Float-type low water cutoff (by others, if used)
1. Blowdown control and test per control manufacturer’s
instructions.
Scald potential. Do not blowdown low water cutoff
unless blowdown piping has been installed according
to control manufacturer’s instructions.If piping is not installed, call
a qualified service technician.
Pilot burner flame
Proper pilot flame (see right):
1. Blue flame.
2. Inner cone engulfing
thermocouple.
3. Thermocouple glowing
cherry red.
Improper pilot flame:
1. Overfired — Large flame
lifting or blowing past
thermocouple.
2. Underfired — Small flame. Inner cone not engulfing
thermocouple.
3. Lack of primary air —Yellow flame tip.
4. Incorrectly heated thermocouple.
Part Number 550-110-739/0703
7
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GSA
Gas-Fired Steam Boilers – User’s Information Manual
❏ End of season
2. Do not drain system unless exposure to freezing temperatures
will occur.
Shutdown procedure
1. Follow “TOTURN OFF GASTO APPLIANCE” on the "Lighting
Instructions" on the inside of the jacket panel.You will also find
these instructions on pages 4 and 5 of this manual.
3. Do not drain the system if it is filled with an antifreeze solution.
4. Do not shut down boilers used for domestic water heating.They
must operate year-round.
Use the "Lighting Instructions" for the gas valve model installed
on the boiler.
❏ Troubleshooting
Troubleshooting — Common problems and possible solutions
Symptom
Common Causes
Possible Corrections
Thermostat installed where drafts or
heat affect reading
Locate thermostat on inner wall away from heat sources or cool drafts.
Adjust thermostat per manufacturer's instructions.
Heat anticipator in thermostat
adjusted incorrectly
Rapid cycling — boiler
turns on and off
frequently
Set limit according to system needs. Maximum setting is 15 psig. Increase limit setting to
decrease cycling.
Incorrect limit setting
Main air vent not working (one-pie
steam) or trap not working (two-pipe Contact service technician to check/replace main air vent or trap
steam)
Frequent release of
water through relief
valve
Inoperative limit control
Leaks in boiler or piping
Call qualified service technician to replace limit control.
Have qualified service technician repair leaks at once to avoid constant use of makeup
water. Makeup water can cause mineral deposits which, in turn, can cause boiler section
failure.
Need to frequently add
makeup water
Oxygen corrosion due to leaks in
boiler and piping
Black water condition
Have qualified service technician repair at once. Keep pH of water between 7.0 to 8.5.
Call qualified service technician to de-lime boiler, if necessary. In some cases, deposits will
be too heavy to remove with de-liming procedures.
Mineral deposits in sections due to
constant use of makeup water
Popping or percolating
noise heard in boiler
Have qualified service technician repair leaks to eliminate need for constant makeup water.
Call qualified service technician to check pH level and correct. pH should be maintained
between 7.0 to 8.5.
Incorrect pH of boiler water
Incorrect piping in Hartford loop
Check-valve inoperative or leaking
Vacuum breaker inoperative
Water disappears from
gauge glass and back
out into system through
return piping
Call qualified service technician to inspect. Correct piping, if necessary, to agree exactly with
Boiler Manual. Clean or replace check valve or vacuum breaker if required.
Remove any contaminating products. See page 2 in this manual.
Contaminated combustion air supply
— See page 2 in this manual.
Metal flakes found in
vent outlet or vent —
flueway corrosion
Provide outside air for combustion. Kit available through local distributor. Have qualified
service technician pipe-up kit.
Condensation of combustion gases
in boiler sections
Have qualified service technician inspect system piping and controls to verify proper
regulation of return water temperature.
Main (or radiator) air vents (one-pipe
Some radiators or
baseboard units do not
heat
steam) or traps (two-pipe steam) not Call qualified service technician to inspect/replace air vents or traps
operating correctly
High limit set too low
Adjust high limit to higher setting.
Dirt, oil or other impurities in water
Call qualified service technician to skim boiler, referring to Boiler Manual for procedure.
Violent waterline
Correct waterline to maximum height of gauge glass, minimum height of ¼” above bottom
of gauge glass.
fluctuations or surging
Waterline too high
Incorrect piping
Call qualified service technician to inspect piping, correcting to exactly as shown in Boiler
Manual, if not as shown.
Water passing into
steam mains — priming
Sudden release of boiler steam
pressure by action of zone valves
Call qualified service technician to inspect, adjusting valves or replacing with slow-opening
valves if necessary.
W-T
8201 W. Calumet Rd.
Milwaukee, WI 53223
8
Part Number 550-110-739/0703
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