Table of Contents
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INSTALLER -
Spark ignition boilers - Refer to this manual
for general installation and maintenance informa-
tion. Refer also to the GSA Spark Ignition Control
Supplement, part number 550-141-971, for operat-
ing instructions, troubleshooting and other additional
information for GSA boilers equipped with spark
ignition.
Hazards that will cause severe personal injury,
death or substantial property damage.
Hazards that can cause severe personal injury,
death or substantial property damage.
INSTALLER - Read all instructions before install-
ing. Read page 2 first. Follow all instructions in
proper order to prevent personal injury or death.
• Consider piping and installation when determining
boiler location.
• Any claims for damage or shortage in shipment
must be filed immediately against the transporta-
tion company by the consignee.
• GSA boilers cannot be adapted for heater use.
This manual must only be used by a qualified heating installer/service technician. Failure to comply could result in
severe personal injury, death or substantial property damage.
When calling or writing about the boiler- Please have: • boiler model number from the boiler rating label and
• CP number from the boiler jacket. You may list the CP number in the space provided on the "Installation and service
certificate" found on page 20.
G SA
Gas-Fired Steam Boilers
Boiler
Contents
1 Prepare boiler location ....................................................... 2
2 Prepare boiler ..................................................................... 8
3 Install piping ..................................................................... 11
4 Install controls .................................................................. 14
5 Install gas piping ............................................................... 15
6 Field Wiring ...................................................................... 16
7 Start-up ............................................................................ 17
8 Checkout procedure ......................................................... 20
9 Service and maintenance ................................................. 21
10 Replacement parts ........................................................... 26
11 Dimensions ....................................................................... 30
12 Ratings ............................................................................. 31
For Operating and Troubleshooting Instructions,
see Spark Ignition Control Supplement
Hazard definitions
• This document is for use only by your qualified
• Please see the User's Information Manual for your
• Have the boiler serviced by a qualified service
Manual
Hazards that will or can cause minor personal
injury or property damage.
Special instructions on installation, operation or
maintenance that are important but not related to
personal injury or property damage.
USER - Please read the following. Failure to
comply could result in severe personal injury,
death or substantial property damage.
heating installer/service technician.
reference.
technician, at least annually.
Part Number 550-110-738/1012
Page
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Table of Contents
Summary of Contents for Milwaukee GSA-075
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Page 1: Table Of Contents
G SA Gas-Fired Steam Boilers Boiler Manual Contents Page 1 Prepare boiler location ............2 INSTALLER — 2 Prepare boiler ..............8 Spark ignition boilers — Refer to this manual 3 Install piping ..............11 for general installation and maintenance informa- tion. -
Page 2: Prepare Boiler Location
GSA Gas-Fired Steam Boilers – Boiler Manual 1 Prepare boiler location Read this first! Failure to adhere to the guidelines below Codes & Checklist can result in severe personal injury, death or substantial property damage. Installations must follow these codes: The boiler contains ceramic fiber and fiberglass •... - Page 3 GSA Gas-Fired Steam Boilers – Boiler Manual 1 Prepare boiler location continued Clearances Recommended SERVICE clearances Clearance for service Minimum Clearance to boiler jacket 1. Provide minimum clearances for cleaning and servicing the boiler and for access to controls and components as listed in Top (for cleaning flueways) 46”...
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Page 4: Residential Garage Installation
“L” width doors and windows and all doors between the space in which length the appliances remaining connected to the common venting GSA-075 –– GSA-100 29 ⅝” 19” system are located and other spaces of the building. Turn GSA-125 –– GSA-150 29 ⅝”... - Page 5 GSA Gas-Fired Steam Boilers – Boiler Manual 1 Prepare boiler location continued Vent System Air contamination Chimney or vent requirements Please review the following information on potential combustion air contamination problems. 1. Venting must be installed according to the National Fuel Gas Code, ANSI Z223.1–latest edition and applicable building See Table 2 for products and areas which may cause contaminated codes.
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Page 6: Air Openings
GSA Gas-Fired Steam Boilers – Boiler Manual 1 Prepare boiler location continued Air openings Provide adequate combustion and ventilation air to • Caulking or sealants are applied to areas such as joints assure proper combustion and reduce the risk of around windows and door frames, between sole plates and severe personal injury, death or substantial property floors, between wall‑ceiling joints, between wall panels, at... -
Page 7: Perform Hydrostatic Pressure Test
GSA Gas-Fired Steam Boilers – Boiler Manual 1 Prepare boiler location continued Pressure test - Setup - continued continued Inspect orifices and burners Do not use petroleum based cleaning or sealing 1. Remove front jacket door. Remove base access panel (see compounds in boiler system. -
Page 8: Prepare Boiler
GSA Gas-Fired Steam Boilers – Boiler Manual 2 Prepare boiler continued Installation of flue collector hood Installation of drawer assembly, (Factory installed on GSA boilers up to GSA-300) Set flue collector hood on boiler as shown in Figure 4. Use boiler front base panels –... -
Page 9: Spill Switch Installation
GSA Gas-Fired Steam Boilers – Boiler Manual 2 Prepare boiler continued Figure 6 Front base panel Figure 9 Burner drawer installation Figure 10 Access panel e m e n t B o i l e r c Figure 7 Burner drawer assembly 6 x ½... -
Page 10: Damper Installation
GSA Gas-Fired Steam Boilers – Boiler Manual 2 Prepare boiler continued Install vent piping 1. Connect from draft hood or vent damper outlet to chimney or vent with same size vent connector. 2. Where possible, vertical venting to the outside from the draft hood or vent damper outlet will offer best performance. -
Page 11: Install Piping
(see Table 6 for recommended sizing) Table 6 Recommended pipe sizing Boiler model number Riser (A) Header (H) Equalizer (J) see Note GSA-075 and GSA-100 2” 2” 1 ½” GSA-125 through GSA-175 2 ½” 2 ½” 1 ½” GSA-200, GSA-250 & GSA-300 3”... -
Page 12: Relief Valve
• When installing the relief valve, ensure that (feet) (feet) (feet) all connections, including the valve inlet, are ½ ½ ½ GSA-075/100 ¾ ¾ clean and free from any foreign matter. 1 ¼ ½ 2 ¼ GSA-125/150 1 ¼... - Page 13 GSA Gas-Fired Steam Boilers – Boiler Manual 3 Install piping continued Condensate return Modern steam boilers are designed to steam for less time than Figure 14 Recommended piping for parallel-flow systems with older, larger boilers. When replacing an older steam boiler the optional reservoir pipe system condensate return time may be longer than the steaming time.
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Page 14: Install Controls
GSA Gas-Fired Steam Boilers – Boiler Manual 4 Install controls Controls Float-type low water cutoff Failure to properly install, pipe and wire boiler (when provided by others) controls may result in severe damage to the boiler, 1. Install low water cutoff as shown in Figure 16, below. See Table building and personnel. -
Page 15: Install Gas Piping
GSA Gas-Fired Steam Boilers – Boiler Manual 5 Install gas piping Connecting gas supply piping to boiler Natural Gas: 1. Remove jacket front panel and see Figure 17 to pipe gas to boiler. 1. See Table 9 for pipe length and diameter. Base on rated a. -
Page 16: Field Wiring
GSA Gas-Fired Steam Boilers – Boiler Manual 6 Field wiring For your safety, turn off electrical power supply at Wiring connections service entrance panel before making any electrical connections to avoid possible electric shock hazard. Boiler is shipped with controls completely wired, except spill switch Failure to do so can cause severe personal injury and vent damper. -
Page 17: Start-Up
GSA Gas-Fired Steam Boilers – Boiler Manual 7 Start-up Preparation Check for gas leaks Skimming the boiler Clean all newly installed steam boilers to remove Be fore starting the boiler, and during initial oper a- oil and grease. Failure to properly clean can result tion, smell near the floor and around the boiler for in violent fluctuations of water level, water passing gas odorant or any unusual odor. -
Page 18: Start The Boiler
GSA Gas-Fired Steam Boilers – Boiler Manual 7 Start-up continued Operate the boiler Check system and boiler DO NOT proceed with boiler operation unless boiler and system have been filled with water Eliminate all system leaks. Continual fresh makeup and all instructions and procedures of previous water will reduce boiler life. - Page 19 GSA Gas-Fired Steam Boilers – Boiler Manual 7 Start-up continued Verify operation Check burner flame — Pilot burner Figure 20 Typical main burner flame Proper pilot flame (see Figure 19): 1. Blue flame. 2. Inner cone engulfing thermocouple. 3. Thermocouple glowing cherry red. Improper pilot flame: 1.
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Page 20: Checkout Procedure
GSA Gas-Fired Steam Boilers – Boiler Manual 8 Checkout procedure Spark ignition boilers: Connect manometer to outlet side of gas valve. Start boiler, allowing for normal start‑up cycle Boiler and heat distribution units filled with water? to occur and main burners to ignite. With main burners on, manually shut off gas supply at manual main shutoff gas Boilers properly skimmed? valve. -
Page 21: Service And Maintenance
GSA Gas-Fired Steam Boilers – Boiler Manual 9 Service and maintenance Table 10 Service and maintenance schedules (service technician and owner) Service technician Owner maintenance (see following pages for instructions) (see User’s Information Manual for instructions) Inspect: ❏ ❏ Daily •... -
Page 22: Reported Problems
GSA Gas-Fired Steam Boilers – Boiler Manual 9 Service and maintenance continued The boiler should be inspected and started o Inspect ..annually, at the beginning of the heating season, only by a qualified service technician. In addition, Piping the maintenance and care of the boiler designated in Table 10, page 22 and explained on the follow-... -
Page 23: Limit Controls
GSA Gas-Fired Steam Boilers – Boiler Manual 9 Service and maintenance continued o Service ..o Check/test ..Gauge glass Low water cutoffs Probe-type low water cutoff (see below) Normal waterline is halfway up gauge glass. - Page 24 GSA Gas-Fired Steam Boilers – Boiler Manual 9 Service and maintenance continued o Check/test ..o Review with owner 1. Review the User’s Information Manual with the owner. Boiler relief valve 2.
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Page 25: Handling Ceramic Fiber And Fiberglass Materials
GSA Gas-Fired Steam Boilers – Boiler Manual Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or base insulation panels in this product contain ceramic fiber materials. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).”: Precautionary measures... -
Page 26: Replacement Parts
25 of this manual. Failure to comply could result in severe personal injury. Item Description Part number Item Description Part number number number Draft hood GSA-075 450-021-255WT Tie rod, " GSA-075 & GSA-100 560-234-470WT GSA-100 450-021-256WT GSA-125 & GSA-150 560-234-475WT GSA-175 & GSA-200 560-234-480WT GSA-125 450-021-257WT GSA-250 560-234-485WT GSA-150 450-021-258WT... - Page 27 25 of this manual. Failure to comply could result in severe personal injury. Item number Description Part number Jacket panel, left side 421-800-150WT Jacket panel, top GSA-075 & GSA-100 421-800-152WT GSA-125 & GSA-150 421-800-153WT GSA-175 & GSA-200 421-800-154WT GSA-250...
- Page 28 GSA Gas-Fired Steam Boilers – Boiler Manual 10 Replacement parts continued Figure 22 Controls and trim Part Number 550-110-738/1012...
- Page 29 GSA Gas-Fired Steam Boilers – Boiler Manual 10 Replacement parts continued Figure 23 For Spark Ignition Gas Controls see GSA Spark Ignition Control Supplement. Part Number 550-110-738/1012...
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Page 30: Dimensions
& manifold size Damper Vent Jacket shipping number height diameter width weight (inches NPT) (inches NPT) (Note 2) (inches NPT) (inches) (inches) (inches) GSA-075 2½ GSA-100 2½ GSA-125 2½ 21¼ GSA-150 2½ 21¼ GSA-175 2½ 25½ GSA-200 2½ 25½ GSA-250 2½... -
Page 31: Ratings
Sq. Ft. Steam (% A.F.U.E.) Steam Btuh (Btuh) (Btuh) (Btuh) Capacity (Output) (Btuh) (Note 3) (Note 1) (Note 4) (Note 2) (Note 3) GSA-075 75,000 62,000 67,500 56,000 47,000 83.0 5"I.D. x 20' GSA-100 100,000 83,000 90,000 75,000 62,000 82.9 5"I.D. - Page 32 GSA Gas-Fired Steam Boilers – Boiler Manual 8201 W. Calumet Rd. Milwaukee, WI 53223 Part Number 550-110-738/1012...
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