Electrical Wiring; Flame Roll-Out; Blocked Vent System - Vaillant GA100CS SERIES Installation And Service Manual

Checking the Gas Piping
Upon completion of piping, chock
right away for gas leaks. Open the
manual shut-off valve. Test for leaks
by applying soap suds (or a liquid
detergent) to each joint. Bubbles
foaming indicate a leak.
CORRECT EVEN THE SMALLEST
LEAK AT ONCE.
WARNING
NEVER USE A MATCH OR OPEN
FLAME TO CHECK FOR LEAKS.
LENGTH
OF PiPE
-FT.
NATURAL GAS
PiPE CAPACITY
CUBIC FEET/HOUR
_" ¾" 1" 1_"
20 74 150 280 580
40 50 100 195 400
60 40 84 155 320
80 34 72 135 275
Fig. 3 - Gas Pipe Capacities
MODEL GA100 CS -60 -80 -100
Elevation
Sea level to 2,000 ft. 38 42 38
2,000 to 5,000 ft. 40 43 41
5,000 to 7,000 ft. 41 44 42
7,000 to 9,000 ft. 42 46 43
9,000 to 10,000 ft. 43 47 44
Fig. 4 - Orifice Size for Natural Gas
MODEL GA100 CS -60 -80 -100
Elevation
Sea level to 2,000 ft. 52 53 52
2,000 to 5,000 ft. 53 55 53
5,000 to 7,000 ft. 53 55 53
7,000 to 9,000 ft. 55 56 54
9,000 to 10,000 ft. 55 56 54
Fig. 5 - Orifice Sizefor Propane (LPG)
Orifice Sizing
All Vaillant GA100 CS series units
are factory equipped with orifices
sized for installation at elevations
ranging from sea level up to 2,000
feet. For higher elevations, smaller
orifices are required to assure safe
operation. Order the proper orifices
e
from your supplier and install them
before turning boiler on. See Figs. 4
&5.
8. Electrical Wiring
Install Your Thermostat.
The thermostat location has an
important effect on the operation of
your boiler system. BE SURE TO
FOLLOW THE INSTRUCTIONS
INCLUDED WITH YOUR THERMO-
STAT.
Locate the thermostat about five
feet above the floor on an inside
wall. It may be mounted vertically on
the wall or on a vertically mounted
outlet box. It should sense average
room temperature, so avoid the fol-
lowing:
Dead Spots:
1. Behind doors
2. Corners and alcoves
Hot Spots:
1. Concealed pipes
2. Fireplaces
3. TV sets
4. Radios
5. Lamps
6. Direct sunlight
7. Kitchens
Cold Spots:
1. Concealed piping or ducts
2. Stairwell drafts
3. Door drafts
4. Unheated rooms on other side
of wall
Control Wiring Diagrams
Field Wiring and Wire Replacement
in the following wiring diagrams
dashed lines .... represent fac-
tory wiring 24V; dashed lines
• • • represent field wiring 24V;
solid lines -- represent factory
wiring 120V; solid lines _ rep-
resent field wiring 120V.
Field wiring, whether for a new
installation or to replace damaged
field or factory installed widng, must
be the type listed below, and must
be installed in accordance with the
National Electric Code and all other
codes and standards covering the
boiler installation.
120-Volt Wiring
All new and replacement wiring
must be U.L. listed and 14-gauge
size (minimum). Install wire in
approved conduit. All terminals and
splices must be in a listed covered
box.
If an external electrical source is uti-
lized, the boiler, when installed,
must be electrically ground in accor-
dance with the requirements of the
authority having jurisdiction or, in
the absence of such requirements,
with the National Electrical Code,
ANSI/NFPA No. 70-Latest Edition.
24-Volt (Low Voltage) Wiring
Use listed low-voltage cable. All
junctions must be clean, joined firm-
ly, and suitably covered with electri-
cal tape or approved wire connec-
tors.
9. Flame Roll Out
The GA100 CS Series is equipped
with a Flame Roll-Out Safety Shut-
Off System. The system is designed
to shut off the boiler if a blockage
occurs in the heat exchanger that
causes flames to roll-out the bottom
of the burner tray. Temperature acti-
vated switch is located on a bracket
next to the pilot or ignitor on the
underside of the burner tray.
When corrective action has been
taken to eliminate the restriction
the pre-set switch has to be
replaced with a Vaillant supplied
replacement.
10. Blocked Vent
System
The GA100 CS Series is equipped
with a =BlockedVent Shut-Off
System'. This system relies on a
temperature sensitive-6witch located
on the side of the draft hood. If the
vent pipe or chimney should
become obstructed to the point of
not completely evacuating the flue
gases, the switch will break and
close down the unit.
When the vent or chimney restric-
tion has been removed, the switch
can be reset.