GVSCIOM-1

GVSC
Gas-Fired Residental Boilers

Boiler Manual
Installation and
Operation Instructions

This manual is intended only for use by a qualified heating installer/technician. Read and follow this manual, all supplements and related
instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these
instructions. Failure to do so can result in severe personal injury, death or substantial property damage.
Do not use the boiler during construction. Construction dust and particulate, particularly drywall dust, will cause contamination of
the burner, resulting in possible severe personal injury, death or substantial property damage. The boiler can only be operated with a dust-
free air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated by operation
with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.
Affix these instructions near to the boiler/water heater. Instruct the building owner to retain the instructions for future use by a qualified
service technician, and to follow all guidelines in the User’s Information Manual.
TABLE OF CONTENTS

TABLE OF CONTENTS
USING THIS MANUAL 3 5. GAS PIPING 15
A. INSTALLATION SEQUENCE . . . . . . . . . . . . .3
6. ELECTRICAL 17
B. SPECIAL ATTENTION BOXES . . . . . . . . . . . .3
A. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1. PREINSTALLATION 4 B. ZONED SYSTEM WIRING . . . . . . . . . . . . . .17
A. ACCESSIBILITY CLEARANCES . . . . . . . . . . .4 C. CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . .17
B. CLEARANCE FROM COMBUSTIBLE D. BOILER SEQUENCE OF OPERATION . . . . .19
CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . .4
7. START-UP PROCEDURES 19
C. PLANNING THE LAYOUT . . . . . . . . . . . . . . .5
A. COMPLETING THE INSTALLATION . . . . . .19
D. MASSACHUSETTS INSTALLATIONS . . . . . .5
B. CONTROL DESCRIPTIONS . . . . . . . . . . . . .23
2. BOILER SET-UP 5 C. ADJUSTMENT OF GAS PRESSURE
REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . .23
3. WATER PIPING AND CONTROLS 6 D. CHECKING BURNER INPUT . . . . . . . . . . . . .23
A. BOILER SUPPLY AND RETURN . . . . . . . . . . .6 E. CHECK-OUT PROCEDURE . . . . . . . . . . . . . .23
B. SAFETY RELIEF VALVE . . . . . . . . . . . . . . . . .7
C. PIPING FOR ZONED SYSTEMS . . . . . . . . . .8 8. TROUBLESHOOTING 25
D. EXPANSION TANK . . . . . . . . . . . . . . . . . . . . .9 A. SHUT-DOWN CAUSED BY PILOT OUTAGE,
PRESSURE SWITCH OR FLAME ROLL-OUT
E. INDIRECT-FIRED WATER HEATER . . . . . . . .9
SAFETY SHUT-OFF SWITCH . . . . . . . . . . . .25
F. FREEZE PROTECTION . . . . . . . . . . . . . . . . . .9
B. TROUBLESHOOTING GUIDES . . . . . . . . . .25
4. VENTING, VENTILATION AND C. MEASURING SUCTION PRESSURE . . . . . .25
AIR INLET 10
9. MAINTENANCE 28
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .10
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .29
B. WALL THIMBLE . . . . . . . . . . . . . . . . . . . . . .10
B. DAILY (WITH BOILER IN USE) . . . . . . . . . . .29
C. ROOF TERMINATIONS . . . . . . . . . . . . . . . .12
C. WEEKLY (WITH BOILER IN USE) . . . . . . . . .29
D. CONDENSATE TRAP INSTALLATION . . . . .12
D. MONTHLY (WITH BOILER IN USE) . . . . . . .29
E. VENT PIPE INSTALLATION . . . . . . . . . . . . .12
E. ANNUALLY (BEFORE START OF HEATING
F. AIR INLET PIPE INSTALLATION . . . . . . . . .14
SEASON) . . . . . . . . . . . . . . . . . . . . . . . . . . .29
G. AIR FOR VENTILATION . . . . . . . . . . . . . . . .14
H. BOILER REMOVAL FROM COMMON 10. BOILER DIMENSIONS & RATINGS 31
VENTING SYSTEM . . . . . . . . . . . . . . . . . . .14
11. REPAIR PARTS 32

2
 USING THIS MANUAL

USING THIS MANUAL

A. INSTALLATION SEQUENCE DANGER
Indicates a condition or hazard which will cause
severe personal injury, death or major property
Follow the installation instructions provided in this

damage.
manual in the order shown. The order of these
instructions has been set in order to provide the installer
with a logical sequence of steps that will minimize
potential interferences and maximize safety during
boiler installation.
WARNING
Indicates a condition or hazard which may cause
severe personal injury, death or major property
B. SPECIAL ATTENTION BOXES

damage.
Throughout this manual you will see special attention
boxes intended to supplement the instructions and make
special notice of potential hazards. These categories mean,
in the judgment of Smith:
CAUTION
Indicates a condition or hazard which will or can
cause minor personal injury or property damage.

NOTICE
Indicates special attention is needed, but not directly
related to potential personal injury or property
damage.

3
PREINSTALLATION

1. PREINSTALLATION
Read carefully, study these instructions before beginning work.
This boiler must be installed by a qualified contractor.
The boiler warranty can be voided if the boiler is not installed, maintained and serviced correctly.

NOTICE
The equipment must be installed in accordance with those installation requirements of the authority having
jurisdiction or, in the absence of such requirements, to the current edition of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or CAN/CSA B49.1, Natural Gas and Propane Installation Code.
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, ANSI/ASME CSD-1.

IMPORTANT
In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a
feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is
equipped with an override which is provided primarily to permit the use of an external energy management
system that serves the same function.
THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:
• An external energy management system is installed that reduces the boiler water temperature as the
heating load decreases.
• This boiler is not used for any space heating
• This boiler is part of a modular or multiple boiler system having a total input of 300,000
BTU/hr or greater.
• This boiler is equipped with a tankless coil.

A. ACCESSIBILITY CLEARANCES DANGER

Do not install this boiler on carpeting. Boiler
installation on carpeting is a fire hazard. Install this
Install boiler not less than 24" (610 mm) between the left

boiler on non-combustible flooring or use a

side, top, and front of the boiler and adjacent wall or other

combustible floor pan to install this boiler on other

appliance, when access is required for servicing.

B. CLEARANCE FROM COMBUSTIBLE non-carpeted flooring.

CONSTRUCTION
The design of this boiler is certified for closet installation WARNING
Liquefied Petroleum (LP) is heavier than air and may
with the following clearances:

collect or “pool” in a low area in the event of a leak

from defective equipment. This gas may then ignite,
1. 6" (152 mm) between right side, front and combustible

resulting in a fire or explosion.

construction.
2. 12" (305 mm) between top of jacket and combustible
construction.
3. 1" (25 mm) between left side, rear and combustible
construction.
4. 2" (51 mm) between vent pipe and combustible
construction.
5. Zero clearance between wall thimble and combustible
construction.
6. This boiler is design certified for use on combustible
flooring.

4
 PREINSTALLATION

C. PLANNING THE LAYOUT • EXEMPTIONS to the requirements listed above:

° The above requirements do not apply if the

Prepare sketches and notes of the layout to minimize the exhaust vent termination is seven (7) feet or
possibility of interferences with new or existing more above finished grade in the area of the
equipment, piping, venting and wiring. Review limitations venting, including but not limited to decks and
on vent pipe, vent terminal, and air inlet pipe locations and porches.
ventilation air requirements in Section 4.
° boilerabove
The requirements do not apply to a
installed in a room or structure separate
D. MASSACHUSETTS INSTALLATIONS from the dwelling, building or structure used in
whole or in part for residential purposes.
Massachusetts requires manufacturers of Side Wall • This boiler installation manual shall remain with the
Vented boilers to provide the following information boiler at the completion of the installation.
from the Massachusetts code:
• A hard wired carbon monoxide detector with an See the latest edition of Massachusetts Code 248 CMR
alarm and battery back-up must be installed on the for complete verbiage and also for additional (non-vent
floor level where the gas equipment is to be related) requirements (248 CMR is available online).
installed AND on each additional level of the
dwelling, building or structure served by the side If your installation is NOT in Massachusetts, please see
wall horizontal vented gas fueled equipment. your authority of jurisdiction for requirements that may
be in effect in your area. In the absence of such
• In the event that the side wall horizontally vented requirements, follow the National Fuel Gas Code, ANSI
gas fueled equipment is installed in a crawl space Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas
or an attic, the hard wired carbon monoxide and Propane Installation Code.
detector with alarm and battery back-up may be
installed on the next adjacent floor level. Venting System Installation Instructions – See boiler
• Detector(s) must be installed by qualified licensed manual and instructions provided with the Venting
professionals. System components. Additional copies may be
obtained from the Venting System Manufacturer by
• APPROVED CARBON MONOXIDE DETECTORS: Each
visiting the following web addresses:
carbon monoxide detector shall comply with NFPA
720 and be ANSI/UL 2034 listed and IAS certified. Heat-Fab – www.selkirkcorp.com/heatfab
• SIGNAGE: A metal or plastic identification plate Z-Flex – www.NovaFlex.com
shall be permanently mounted to the exterior of Pro-Tech – www.protechinfo.com
the building at a minimum height of eight (8) feet
above grade directly in line with the exhaust vent
terminal for the horizontally vented gas fueled
heating appliance or equipment. The sign shall
read, in print size no less than one-half (1/2) inch in
size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR
OF ALL OBSTRUCTIONS”.

2. BOILER SET-UP
1. Provide a sound, level foundation. Locate boiler as near 4. Separate the wood shipping pallet from the boiler base
to the outside wall as possible and centralized with by removing two (2) hold-down bolts at each end of
respect to the heating system. the boiler base.

2. Locate boiler in front of installation position before 5. Move boiler into final position.
removing crate.

5
WATER PIPING AND CONTROLS

3. WATER PIPING AND CONTROLS

A. BOILER SUPPLY AND RETURN 3. Supply Piping:
a. Pipe the supply to the 1-1/2" NPT supply tapping at
1. Size the supply and return to suit the system. A typical the top of the boiler.
piping arrangement is shown in Figure 3.1. Refer also
to the Hydronics Institute Residential Hydronic Heating b. Provide clearance to venting system
Installation Design Guide for additional guidance (see Section 4).
during water piping installation.
4. When system return water temperature will be below
2. Return Piping: 130°F (54°C), pipe the boiler with a bypass
Pipe the outlet connection of the circulator to a tee, arrangement to blend the system return and hot
provided with a drain valve, at the 1-1/4" NPT return supply to obtain at least 130°F (54°C)entering the
tapping near the bottom of the right section. Pipe the boiler.
return to the inlet connection of the circulator.
5. If desired, install the circulator in the alternate location
shown in Figure 3.1.

Figure 3.1: Supply and Return Piping

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 WATER PIPING AND CONTROLS

6. Install this boiler so that the gas ignition system

components are protected from water (dripping,
spraying, etc.) during appliance operation and service
(circulator replacement, condensate trap, control
replacements, etc.).

7. If this boiler and distribution system is used in

conjunction with a refrigeration system, pipe the
chilled medium in parallel with the boiler and install
the proper valve to prevent the chilled medium from
entering the boiler. A drawing illustrating this hook-up
is provided in Figure 3.2.

8. When the boiler is connected to heating coils located

in air handling units where they may be exposed to
refrigerated air circulation, install flow control valves or
other automatic means to prevent gravity circulation of
the boiler water during the cooling cycle.
Figure 3.3: Safety Relief Valve Hook-Up
9. If this boiler is installed above radiation level, provide a
Installation with Air Elimination in
low water cutoff device, either as a part of the boiler or
System Piping
at the time of boiler installation.

B. SAFETY RELIEF VALVE

1. Locate safety relief valve and fittings in bag assembly.

2. If air elimination is not required at the safety relief

valve tapping, install valve and piping as shown in
Figure 3.3.

3. For air elimination at the safety relief valve tapping,

install valve and piping as shown in Figure 3.4.

CAUTION
Pipe the discharge of safety relief valve to prevent
injury in the event of pressure relief. Pipe the
discharge to a drain. Provide piping that is the same
size as the safety relief valve outlet.

Figure 3.4: Safety Relief Valve Hook-Up with

Air Elimination

Figure 3.2: Parallel Hook-up with Water Chiller

7
WATER PIPING AND CONTROLS

C. PIPING FOR ZONED SYSTEMS

1. See Figures 3.5 and 3.6 for basic zoned system layouts.

2. Run each zone pipe down then up to zone to prevent

air accumulation in piping.

3. If required, provide means to isolate and drain each

zone separately.

Figure 3.5: Zone Piping with Zone Valves

Figure 3.6: Zone Piping with Circulators

8
 WATER PIPING AND CONTROLS

D. EXPANSION TANK F. FREEZE PROTECTION

1. Consult the tank manufacturer’s instructions for For new or existing systems that must be freeze-protected:
specific information relating to tank installation. Size
the expansion tank for the required system volume and WARNING
Use only inhibited propylene glycol solutions of up
capacity. See Table 10.2 in Section 10 for boiler water

to 50% by volume with water. Ethylene glycol is toxic

capacity.

and can attack gaskets and seals used in hydronic

systems.
2. Expansion tanks are available with built-in fill valves
and check valves for reducing supply water pressure
and maintaining minimum system pressure. Check the
design features of the tank and provide valves as
necessary. 1. Glycol in hydronic applications is specially formulated
for this purpose. It includes inhibitors which prevent
Refer back to Figure 3.1 for typical expansion tank piping.
the glycol from attacking metallic system components.
Make certain that the system fluid is checked for the
E. INDIRECT-FIRED WATER HEATER correct glycol concentration and inhibitor level.

If the boiler is to be used in conjunction with an indirect- 2. The glycol solution should be tested at least once a
fired water heater, refer to Figure 3.7 for typical piping. year and as recommended by the antifreeze
Follow the instructions provided by the water heater manufacturer.
manufacturer. Pipe the water heater as a separate zone.
3. Glycol solutions expand more than water. For example,
a 50% by volume solution expands 4.8% in volume for
a temperature increase from 32°F (0°C) to 180°F (82°C) ,
while water expands 3% with the same temperature
rise. Allowance must be made for this expansion in
system design.

A. GENERAL

Figure 3.7: Typical Piping with Indirect-Fired Water Heater

9
VENTING, VENTILATION AND AIR INLET

4. VENTING, VENTILATION AND AIR INLET

A. GENERAL c. Provide 2" (51 mm) clearance between vent pipe
and combustible construction. No clearance is
Install vent system in accordance with Venting of required between Thimble and combustible
Equipment part of the National Fuel Gas Code, ANSI construction.
z223.1/NFPA 54 or sections 7.2, 7.3 or 7.4 of CAN/CSA
B149.1, Natural Gas and Propane Installation Code. d. Provide 3 feet (1 meter) clearance above any forced
air inlet within 10 feet (3 meters).
WARNING
This vent system will operate with a positive
e. Provide 1 foot (0.3 meters) clearance below and 1

pressure in the vent pipe. Do not connect vent

foot (0.3 meters) beside, or 1 foot (0.3 meters)

connectors serving appliances vented by natural

above any door, window, or gravity air inlet into

draft into any portion of mechanical draft systems

any building.

operating under positive pressure.

f. Provide 1 foot (0.3 meters) clearance between
bottom of vent terminal and ground level and
normal snow lines.
WARNING
All joints of positive pressure vent systems must be
g. Provide 4 feet (1.2 meters) horizontal clearance

sealed completely to prevent leakage of flue

from electric meters, gas meters, regulators and

products into the living space.

relief equipment. In Canada, this dimension must
be 6 feet (2 meters).

h. Do not locate vent terminal over public walkways

where condensate could create a nuisance or hazard.
NOTICE
Flue gases will condense as they exit the vent
i. When adjacent to a public walkway, locate vent
termination. This condensate can freeze on exterior
terminal at least 7 feet (2.1 meters) above grade.
building surfaces which may cause discoloration of
these surfaces.
j. Do not locate directly under roof overhangs to
prevent icicles from forming.
B. WALL THIMBLE (SIDEWALL
2. Cut a 5-1/8" (130 mm) square hole in sidewall to allow
VENTING ONLY)
wall thimble to go through.
1. Determine vent cap (terminal) location.
3. Insert Thimble from inside wall with 4" (102 mm)
a. Must be within the maximum and minimum vent diameter air inlet connection facing down. Extend
and air intake lengths shown in Tables 4.1 and 4.2. Thimble 3-1/2" (89 mm) past outside wall surface. The
cut-out opening of thimble is pointed down.
b. Maximum wall thickness for the 19-1/2" (495 mm)
long Wall Thimble (standard) is 11-1/2" (292 mm). 4. Use a minimum 2-1/2 foot (762 mm) piece of 3"
Maximum wall thickness for the optional 28" (711 (76 mm) diameter AL29-4C stainless steel vent pipe for
mm) long thimble is 20" (508 mm). insertion through Wall Thimble. See Vent Pipe section
below for vent pipe requirements.

Figure 4.1: Wall Thimble

10
 VENTING, VENTILATION AND AIR INLET

5. Slide Stainless Steel Collar over vent pipe and slide to 11. Secure Inside Thimble cap to Wall Thimble with #10
end of pipe. screws. Seal Thimble Cap perimeter with silicone.

6. Insert pipe with collar through Outside Vent Cap and 12. Seal all openings between Wall and Thimble and
slide 3" (76 mm) diameter hose clamp over collar. around the 3" (76 mm) diameter stainless steel vent
pipe that protrudes through inside and outside of Wall
7. Leave at least 2" (51 mm) of vent pipe protruding Thimble.
beyond face of Vent Cap and secure hose clamp and
collar to vent pipe. 13. Add any bracing that may be needed to support Wall
Thimble on inside of wall structure.
8. Place Outside Vent Cap over Wall Thimble with air
openings in Vent Cap facing down. Secure Cap to 14. Secure Outside Vent Cap to exterior wall with four #10
Thimble with #10 sheet metal screws. sheet metal screws provided.

9. Place 3" (76 mm) diameter hose clamp over pipe 15. Attach Z-Flex #2SVSTPF03 terminal to protruding vent
protruding through inside of Wall Thimble. pipe. Refer to Figure 4.2. To attach to HEAT-FAB pipe,
insert into pipe end and fold over tabs to secure.
10. Place Inside Thimble Cap and Collar onto Wall Thimble. Otherwise, silicone terminal to vent pipe.
Access hose clamp through 4" (102 mm) diameter
collar on bottom of Thimble and secure hose clamp
over collar and vent pipe as per step 7 above.

Figure 4.2: Side Wall Venting System

11
VENTING, VENTILATION AND AIR INLET

C. ROOF TERMINATIONS (VERTICAL E . VENT PIPE INSTALLATION

VENTING)
1. For minimum and maximum vent pipe lengths see
1. Vent pipe and air inlet terminations must be within the Table 4.1.
maximum and minimum vent and air intake lengths
shown in Tables 4.1 and 4.2. 2. Use only 3" (76 mm) diameter Type AL29-4C stainless
steel vent pipe and fittings for venting of
flue gases from the boiler. When using other than
Table 4.1
Heat-Fab vent pipe, an adapter must be installed
*Equivalent Length of 3" (76 mm) Diameter on the outlet of condensate elbow. See Figure 4.2.
Stainless Steel Vent Pipe Adapter part numbers are as follows:
Boiler Model Minimum Vent Length Maximum Vent Length
GVSC-03 8 feet (2.5 m) 52 feet (15.5 m) Pipe Manufacturer Adapter
GVSC-04 8 feet (2.5 m) 52 feet (15.5 m)
Flex-L Star-34 SRAPSCA3*
GVSC-05 8 feet (2.5 m) 45 feet (13.5 m)
GVSC-06 8 feet (2.5 m) 45 feet (13.5 m) Heat-Fab Saf-T Vent Adapter not required

ProTech FasNSeal FSA-HFA3*

Table 4.2 Z-Flex Z-Vent 2SVSSLA2*

*Equivalent Length of 4" (102 mm) Diameter * Available from Vent Pipe Manufacturer
Aluminum/Galvanized Air Inlet Pipe
Boiler Model Minimum Length Maximum Length 3. Attach remaining pipe and fittings per each
GVSC-03 12 feet (4.0 m) 70 feet (21.0 m) manufacturer’s vent instructions. Use only the silicone
recommended by vent pipe manufacturers. Maintain
GVSC-04 12 feet (4.0 m) 70 feet (21.0 m)
proper clearance to combustible construction – see
GVSC-05 12 feet (4.0 m) 63 feet (19.0 m) Section 1, Preinstallation.
GVSC-06 12 feet (4.0 m) 63 feet (19.0 m)
4. Horizontal portions of the vent pipe shall slope upward
* Each 90° elbow equals 5 feet (1.5 meters) of equivalent length. from the boiler towards the vent termination, not less than
1/4" per foot (21 mm per meter).
2. Vent pipe and air inlet pipe must terminate 12" Parties horizontales de l'évent doit pente ascendante de
(305 mm) above expected snow lines. Vent pipe must la chaudière vers la terminaison de ventilation, pas
be a minimum 12" (305 mm) above and 12" (305 mm) moins de 1/4 "par pied (21 mm par mètre).
horizontally from air inlet pipe. See Figure 4.3.
5. Support horizontal lengths of the vent system to
3. Attach a vent manufacturer's listed rain cap to both the prevent sagging by use of metal strapping or
vent pipe and air inlet pipe. equivalent means. Locate supports at not more than
four (4) foot intervals.
4. Provide 2" (51 mm) clearance between vent pipe and
combustible construction. No clearance is required Fournir un support à toute portion horizontale du
between air inlet pipe and combustible construction. système d’évacuation à l’aide de courroies de metal ou
une méthode équivalente afin de l’empêcher de
5. See vertical venting section in vent manufacturer's s’affaisser. Placer les supports à des intervalles ne
instructions for recommendations for penetration dépassant pas cent vingt deux (122) centimètres (4 po),
through roof. ou en suivant les recommandations d’ installation du
fabricant.

D . CONDENSATE TRAP INSTALLATION 6. Vertical Venting Only – If there is no solid anchor

point in the system below the roof for supporting
Locate condensate hose and cable tie in Accessory Carton. vertical sections of the vent pipe (i.e. Firestop
Connect hose to drain fitting on condensate elbow. Form a Support, etc.), a special vent support system will be
3" diameter loop and secure with cable tie. Fill loop with required. See vent manufacturer's instructions for
water. Pipe to drain or condensate receiver. See Figure 4.2. additional information.

12
 VENTING, VENTILATION AND AIR INLET

Figure 4.3: Vertical Venting System

13
VENTING, VENTILATION AND AIR INLET

F. AIR INLET PIPE INSTALLATION not connected to common venting system. Turn on
any exhaust fans, such as range hoods and bathroom
1. For maximum air inlet pipe lengths see Table 4.2. exhausts, so they will operate at maximum speed. Do
not operate a summer exhaust fan. Close fireplace dampers.
2. Use only 4" (102 mm) diameter galvanized pipe or 4" Dans la mesure du possible, fermer toutes les portes et
(102 mm) diameter flexible aluminum vent for fenêtres de l’immeuble ainsi que toutes les portes entre
supplying combustion air to boiler inlet air box. l’espace dans lequel les appareils qui demeurent raccordés
au système d’évacuation commun se trouvent et le reste
3. Boiler connection can be from either right or left side
de l’immeuble. Mettre en marche les sécheuses et tout
of boiler jacket. Determine which jacket side air inlet
autre appareil non raccordé au système d’évacuation
piping is to be routed and remove the 4-1/2" (114 mm)
commun. Mettre en marche tous les ventilateurs aspirant,
jacket knock-out.
tels que les hottes de cuisinière et les ventilateurs de salle
4. Attach a 4" (102 mm) diameter 90 degree elbow to top de bain, en les faisant fonctionner à vitesse maximum. Ne
of air box and connect air inlet piping. pas faire fonctionner les ventilateurs aspirant d’été. Fermer
les registres de foyers.
5. Support air inlet piping using the same methods and d. Place in operation the appliance being inspected.
requirements as shown in the previous section for vent Follow the lighting instructions. Adjust thermostat so
pipe support. appliance will operate continuously.

6. Seal all connections using silicone. Mettre en service l’appareil à inspecter. Suivre les
instructions concernant l’allumage. Régler le
7. To prevent condensation from forming on exposed thermostat afin que l’appareil fonctionne sans arrêt.
portions of Wall Thimble and 4" (102 mm) diameter air e. Test for spillage at the draft hood relief opening after 5
inlet piping, wrap exposed areas with insulation. minutes of main burner operation. Use the flame of a
match or candle, or smoke from a cigarette, cigar, or pipe.
G. AIR FOR VENTILATION Vérifier toute fuite à l’orifice de décharge du coupe-
tirage après que le brûleur ait fonctionné pendant 5
1. Provide air openings for adequate ventilation to minutes. Utiliser la flamme d’une allumette ou d’une
prevent ambient boiler room temperature from chandelle ou encore la fumée d’une cigarette, d’un
exceeding 120°F (49°C) during boiler operation. This is cigare ou d’une pipe.
to maintain all the boiler controls below maximum f. After it has been determined that each appliance
service temperatures. Openings should be fixed in the remaining connected to the common venting system
open position during operation. properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers and
any other gas-burning appliance to their previous
H. BOILER REMOVAL FROM COMMON conditions of use.
VENTING SYSTEM
Après avoir établi que les résidus de combustion de
At the time of removal of an existing boiler, follow these chaque appareil qui demeure raccordé au système
steps with each appliance remaining connected to the commun sont adéquatement évacués lorsque soumis
common venting system placed in operation, while the au test décrit ci-dessus, remettre en place les portes,
other appliances remaining connected to the common fenêtres, portes intérieures, ventilateurs aspirants,
venting system are not in operation: registres de foyer et appareils fonctionnant au gaz.
g. Any improper operation of the common venting
Au moment de retirer une chaudière existante, il est important system should be corrected so that the installation
de suivre les étapes suivantes pour chaque appareil raccordé conforms with the current edition of the National Fuel
au système d’évacuation commun qui sont en service, alors Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA
que les autres appareils demeurant raccordés au système B149.1, Natural Gas and Propane Installation Code.
d’évacuation commun ne sont pas en service: When resizing any portion of the common venting
a. Seal any unused openings in the common venting system. system, the common venting system should be resized
Sceller toute ouverture du système d’évacuation to approach the minimum size as determined using the
commun non utilisée. appropriate tables in the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas
b. Visually inspect the venting system for proper size and and Propane Installation Code.
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other deficiencies Tout fonctionnement inadéquat du système
which could cause an unsafe condition. d’évacuation commun doit être corrigé de manière à
respecter les normes du National Fuel Gas Code, ANSI
Effectuer un contrôle visuel du système d’évacuation pour Z223.1/NFPA 54 et/ou des Codes d’installation
vérifier la taille et la pente horizontale et s’assurer qu’il CAN/ACG B149. Lorsqu’il est nécessaire de modifier les
n’existe aucun blocage ou obstruction, fuite, corrosion ni dimensions de toute portion du système d’évacuation
tout autre problème pouvant menacer la sécurité. commun, ces dernières doivent être modifiées de
c. Insofar as is practical, close all building doors and manière à respecter les dimensions minimums
windows and all doors between the space in which the indiquées dans les tableaux du chapitre « Sizing of
appliances remaining connected to the common Category I Venting Systems » du National Fuel Gas
venting system are located and other spaces of the Code, ANSI Z223.1/NFPA 54 ou des Codes d’installation
building. Turn on any clothes dryers and any appliance CAN/ACG B149

14
 GAS PIPING

5. GAS PIPING
1. Size and install the gas supply piping properly in order
to provide a supply of gas sufficient to meet the
maximum demand without undue loss of pressure
between the meter and the boiler.

2. Determine the volume of gas to be provided to the

boiler in cubic feet per hour. To obtain this value,
divide the Btu per hour rating (on the boiler rating
plate) by the heating value of the gas in Btu per cubic
feet. Obtain the heating value of the gas from the gas
supplier. As an alternative, use Table 5.1 on the next
page to obtain the volume of gas to be provided to the
boiler.

3. Use the value obtained above as the basis for piping

sizing. Size the gas piping in accordance with Table 5.2.
Consult the National Fuel Gas Code, ANSI Z223.1/NFPA
54 and/or CAN/CSA B149.1, Natural Gas and Propane Figure 5.1: Gas Connection to Boiler
Installation Code.
8. Disconnect the boiler and its individual shut-off valve
4. Locate the drop pipe adjacent to, but not in front of from the gas supply piping system during any pressure
the boiler. testing of that system at test pressure in excess of 1/2
psig (3.5 kPa).
5. Install a sediment trap. See Figure 5.1. Locate a tee in
the drop pipe at same elevation as the gas inlet Isolate the boiler from the gas supply piping system by
connection to the boiler. Extend the drop pipe to a closing its individual service valve during any pressure
pipe cap. testing of the gas supply piping system at test pressure
equal to or less than 1/2 psig (3.5 kPa).
6. Install a ground joint union ahead of the gas control
assembly to permit servicing of the control. Some local
CAUTION
Do not subject the gas valve to more than 1/2 psi
codes require an additional service valve when using

(3.5 kPa) pressure. Doing so may damage the valve.

the combination gas controls. If your code requires
such a valve, a suggested location is shown in Figure
5.1.

WARNING 9. Minimum permissible supply pressure for purposes of

Use a pipe joint sealing compound that is resistant to

input adjustment (Inches Water Column):

the action of liquefied petroleum gas. A non-resistant

Natural Gas 5.0" (1.2 kPa)

compound may lose sealing ability in the presence of

LP Gas 11.0" (2.7 kPa)

this gas, resulting in a gas leak and fire or explosion

potential.
Maximum permissible supply pressure to the boiler
(Inches Water Column):
Natural Gas 13.5" (3.4 kPa)
LP Gas 13.5" (3.4 kPa)
7. Check piping for leaks prior to placing the boiler in
operation.
Use an approved gas detector, a non-corrosive leak
detection fluid or other leak detection method. If leaks
are found, turn off all gas flow and repair as necessary.

WARNING
When checking for leaks, do not use matches,
candles, open flames or other methods that provide a
source of ignition. This can ignite a gas leak,
resulting in fire or explosion.

15
GAS PIPING

Table 5.1: Natural Gas

Boiler Natural Gas Input LP Gas Input

Model Cu. Ft/hr Cu. Meter/hr Cu. Ft/hr Cu. Meter/hr
GVSC-03 65 1.8 26 0.7
GVSC-04 90 2.5 36 1.0
GVSC-05 120 3.4 48 1.4
GVSC-06 150 4.2 60 1.7

Table 5.2: Pipe Capacity

Capacity of pipe of different diameters and lengths in cubic feet per hour (cubic meter per
hour) with pressure drop of 0.3 inches of water (75 Pa) and specific gravity of 0.60. No
allowance for an ordinary number of fittings is required.

Pipe
3/4" 1" 1-1/4" 1-1/2"
Length in
Pipe Pipe Pipe Pipe
Feet (Meters)

10 (3.0) 278 (7.9) 520 (14.7) 1050 (29.7) 1600 (45.3)

20 (6.1) 190 (5.4) 350 (9.9) 730 (20.7) 1100 (31.1)
30 (9.1) 152 (4.3) 285 (8.1) 590 (16.7) 890 (25.2)
40 (12.2) 130 (3.7) 245 (6.9) 500 (14.2) 760 (21.5)
50 (15.2) 115 (3.3) 215 (6.1) 440 (12.5) 670 (19.0)
60 (18.3) 105 (3.0) 195 (5.5) 400 (11.3) 610 (17.3)

Maximum Capacity Correction Factors for Specific Gravity

other than 0.60.
Specific Gravity 0.50 0.55 0.60 0.65 0.70 0.75
Correction Factor 1.10 1.04 1.00 0.96 0.93 0.90
Specific Gravity 0.80 0.85 0.90 1.00 1.10 1.20
Correction Factor 0.87 0.84 0.82 0.78 0.74 0.71
Specific Gravity 1.30 1.40 1.50 1.60 1.70 1.80
Correction Factor 0.68 0.66 0.63 0.61 0.59 0.58

16
 ELECTRICAL

6. ELECTRICAL
Install all electrical wiring in accordance with the National Electric Code and local requirements.

NOTICE
This unit when installed must be electrically grounded in accordance with the requirements of the authority
having jurisdiction or, in the absence of such requirements, with the current edition of the National Electrical
Code, ANSI/NFPA 70 and/or the Canadian Electrical Code, Part 1, CSA C221.

A. WIRING B. ZONED SYSTEM WIRING

See Figure 6.4 for typical wiring with zone valves. See
CAUTION Figure 6.5 for typical wiring with zone circulators. When

Label all wires prior to disconnection when servicing

wiring a zoned heating system, follow all applicable codes,

controls. Wiring errors can cause improper and

ordinances and regulations.

dangerous operation. Verify proper operation after

servicing.
NOTICE
Do not power zone valves directly from the boiler
transformer. Doing so will greatly reduce the life of
the transformer. Use a separate transformer sized to
handle the total of all zone valve electrical loads.
AVERTISSEMENT
Identifier tous les câbles avant de les débrancher au
moment d’effectuer l’entretien des commandes. Des
erreurs dans le raccordement des câbles
d’alimentation peuvent causer un fonctionnement
C. CONTROLS
inadéquat et dangereux. Vérifier le bon
fonctionnement après les travaux d’entretien.
1. For proper location of controls and accessories refer to
Figure 6.1.

1. See Figure 6.1 for location of wiring and controls. Use 2. See the attached control sheets for specific details
Figure 6.2 to connect the boiler to a power supply and regarding the installation of the various controls.
to connect components to the boiler.
3. This boiler is supplied with safety devices in addition to
2. Connect the boiler by a separate, permanently live the limit. For a description of these devices and how
electrical supply line with a fused switch. they work to ensure the safe operation of the boiler,
see Section 7.
3. Adjust the thermostat heat anticipator to 0.2 Amp.
4. If the circulator is mounted in the supply piping,
provide longer wiring harness as required.

Figure 6.1: Wiring, Controls and Safety Devices

17
ELECTRICAL

Figure 6.2: Wiring Diagram, Spark Ignited Pilot, Becket 7600 Limit Control

Figure 6.3: Wiring Diagram, Spark Ignited Pilot, Hydrolevel 3200 Limit control

18
 ELECTRICAL

D. BOILER SEQUENCE OF OPERATION 7. Pilot flame detected.

a. Ignitor off.
1. Thermostat calls for heat.
b. Main gas on, igniting main burners.
2. Limit control energizes circulator.
Note: If pilot flame is not detected within 90 seconds,
3. Limit control energizes B1 circuit if boiler water the igniter and pilot are turned off for 5 minutes. The
temperature is below setpoint minus differential. sequence then resumes at Step 6a.
Setpoint is calculated according to thermostat cycle
8. Call for heat ends.
and economy/efficiency setting. See limit control
literature for further information. a. Pilot and main gas off, extinguishing pilot and main
burners.
4. BR relay energizes blower.
b. Blower and circulator off.
5. Negative pressure induced by blower switches Pressure
Switch, continuing power through closed contacts (BR-
2) and flame roll-out switch.

6. Gas valve energizes.

a. Ignitor on.

b. Pilot gas on, igniting pilot

7. START-UP PROCEDURES
A. COMPLETING THE INSTALLATION 7. Check joints and fittings throughout the system for
leaks. If leaks are found, drain the system and repair as
1. Confirm that all water, gas and electricity are required.
turned off.
8. Connect a manometer to the 1/8" NPT inlet pressure
2. Inspect the boiler combustion chamber for foreign tap on the gas valve. See Figure 7.2.
objects and remove if present.
9. Confirm that the gas supply pressure to the boiler is
3. Check physical condition of burners and pilot. Make above the minimum and below the maximum values
certain that there are no unusual bends or perforations for the gas being used. See the end of Section 5 for
in the burners or pilot. Replace components if these values. If a supply pressure check is required,
necessary. isolate the boiler and gas valve before performing the
pressure check. If the supply pressure is too high or too
4. Verify that water piping, venting, gas piping and low, contact the gas supplier.
electrical wiring and components are installed
properly. Refer back to previous sections of these 10. Turn on electricity and gas to boiler.
instructions as well as equipment manufacturer’s
instructions as necessary. 11. Light the boiler by following the Lighting/Operating
Instructions label mounted to the jacket panel. The
5. Fill the boiler and system with water, making certain to initial ignition may require several tries as the piping is
vent all air from all points in the system. To check water purged of air.
level in the system, open and close each vent in the
system. Water should exit from each vent when it is 12. Use the sequence description and Figure 6.3 in Section
opened. 6 (Electrical) to follow light-off and shutdown
sequences and to assist in diagnosing problems. If the
6. The pressure reducing valve on the fill line will typically boiler does not function properly, consult Section 8,
allow the system to be filled and pressurized to 12 psi Troubleshooting.
(83 kPa). Consult the valve and expansion tank
manufacturer for more specific information.

19
START-UP PROCEDURES

Figure 7.1: Gas Valve, Manifold and Burner Assembly – Intermittent Ignition

Figure 7.2: Valve Tapping and Adjustment Screw Locations

20
 START-UP PROCEDURES

Figure 7.3: Operating Instructions

21
START-UP PROCEDURES

Figure 7.4: Operating Instructions

22
 START-UP PROCEDURES

B. CONTROL DESCRIPTIONS D. CHECKING BURNER INPUT

See Figure 6.1 in Section 6 (Electrical) for locations of these 1. Refer to rating label mounted on the jacket top panel
devices. to obtain the rated BTU per hour input. In no case shall
the input to the boiler exceed the value shown on the
1. FLAME ROLL-OUT SAFETY SHUT-OFF SWITCH (FLAME rating label.
ROLL-OUT SWITCH) – A thermally activated switch
located between the first burner from the left and the 2. Check input by use of the following formula
manifold bracket. The flame roll-out safety shut-off (Smith suggests reading meter for 2 Cu.Ft. [0.0566
switch will sense excessive temperature caused by cubic meter]):
continued flame roll-out and shut down main burner
gas. This is a non-recycling switch that must be U.S. Customary Units:
replaced once it has been activated and the cause of Input (BTU/Hr.)= 3600 x F x H
the roll-out eliminated. T
Where:
2. DIFFERENTIAL PRESSURE SWITCH – This device senses a 3600 – Seconds per hour
negative or suction pressure in the blower housing and F – Cubic Feet of Gas Registered on Meter
air box when the blower is energized. If there is not H – Heat Value of Gas in BTU/Cubic Feet
excessive blockage in the venting system or air inlet T – Time in Seconds the Meter is Read
vent the switch will close, allowing power to energize
the ignition system. SI Metric Units
Input (kW)= 3600 x F x H
3. LIMIT WITH LOW WATER CUT-OFF– A Beckett 7600B or T x 3.6
Hydrolevel 3200 control incorporate a thermally Where:
activated adjustable switch that will shut down main 3600 – Seconds per hour
burner gas if the supply water temperature exceeds
3.6 – Megajoule (MJ) per kilowatt hour (kWhr)
the control setting It will also shut down main burner
gas if the water level in the boiler drops below the F – Cubic Meters of Gas Registered on Meter
control’s sensing well. The temperature switch will H – Heating Value of Gas in MJ/Cubic Meter
automatically reset when the boiler supply water T – Time in Seconds the Meter is Read
temperature drops below the control setpoint. The low
water cut-off switch will automatically reset when the 3. As an alternative, use Table 7.1a and 7.1b. Use the
water level is above the control’s sensing well. heating value provided by gas supplier. Use a
stopwatch to record the time it takes for 2 cubic feet
4. LOW WATER CUT-OFF (FOR GRAVITY SYSTEMS OR HOT (0.0566 cubic meter) of gas to pass through the meter.
WATER BOILERS INSTALLED ABOVE RADIATION LEVEL) Read across and down to determine rate.
– A level-sensing device (float or probe) located in
supply piping near the boiler. If water level in the
system drops below the control’s position, it will shut E. CHECK-OUT PROCEDURE
down main burner gas. The control will automatically
1. After starting the boiler, be certain all controls are
reset once the water level rises above its position.
working properly. Check to be sure that the limit will
shut off the boiler in the event of excessive water
C. ADJUSTMENT OF GAS PRESSURE temperature. This can be done by lowering the limit
setting until the main burners shut down. When proper
REGULATOR limit function is confirmed, return the dial to its
1. Move the manometer to either the outlet pressure tap previous setting.
on the gas valve or to the burner manifold test tap. Set
2. To check operation of the ignition system safety
manifold pressure as follows for various gases.
shut-off features:
a. Natural Gas . . . . . . .3.5" Water Column (0.9 kPa)
a. Turn gas supply off.
b. LP Gas . . . . . . . . . .10.0" Water Column (2.5 kPa)
b. Set thermostat or controller above room
2. To adjust gas pressure, turn adjusting screw of gas temperature to call for heat. Watch for igniter spark
pressure regulator counterclockwise to decrease at pilot burner.
pressure, clockwise to increase pressure. Refer to Figure
7.2 for location of gas pressure regulator. Replace the c. Igniter will continue to spark for 90 seconds.
cap screw when adjustment is complete. It will then de-energize for 5 minutes before
restarting the sequence.
3. In no case should the final manifold pressure vary more
than ±0.3 inches water column (0.07 kPa) from the d. Turn gas supply on.
above specified pressures. Any necessary major e. Reset the boiler and control by following Operating
changes in the flow should be made by changing the Instructions.
size of the burner orifice spuds.
f. Observe boiler operation through one complete
4. When adjustment is complete, turn off boiler, gas flow cycle.
and electricity to boiler. Remove manometer and plug
tapping with plug provided. Turn utilities back on and
resume checkout.

23
START-UP PROCEDURES

Table 7.1a: Meter Conversion Natural Gas Table 7.1b: Meter Conversion Natural Gas
(U.S. Customary Units) (SI Metric System)

Burner inputs in Btu/hr for various meter timings and Burner inputs in kW for various meter timings and
heating values. (Tables based on 2 cubic feet of gas heating values. (Tables based on 0.0566 cubic meters of
through the meter). gas through the meter).

Time that Heat Value of Gas Time that Heat Value of Gas
meter is (Btu/cubic foot) meter is (MJ/cubic meter)
read (sec) 1000 1025 1050 read (sec) 37.26 38.19 39.12

25 288000 295200 302400 25 84.36 86.46 88.57

30 240000 246000 252000 30 70.30 72.05 73.81
35 205714 210857 216000 35 60.25 61.76 63.26
40 180000 184500 189000 40 52.72 54.04 55.35
45 160000 164000 168000 45 46.86 48.03 49.20
50 144000 147600 151200 50 42.18 43.23 44.28
55 130909 134182 137455 55 38.34 39.30 40.26
60 120000 123000 126000 60 35.15 36.03 36.90
65 110769 113538 116308 65 32.44 33.25 34.06
70 102857 105429 108000 70 30.13 30.88 31.63
75 96000 98400 100800 75 28.12 28.82 29.52
80 90000 92250 94500 80 26.36 27.02 27.68
85 84706 86824 88941 85 24.81 25.43 26.05
90 80000 82000 84000 90 23.43 24.02 24.60
95 75789 77684 79579 95 22.20 22.75 23.31
100 72000 73800 75600 100 21.09 21.62 22.14
105 68571 70286 72000 105 20.08 20.59 21.09
110 65455 67091 68727 110 19.17 19.65 20.13
115 62609 64174 65739 115 18.34 18.80 19.25
120 60000 61500 63000 120 17.57 18.01 18.45
125 57600 59040 60480 125 16.87 17.29 17.71

3. Low Water Cut-Off (if used) – Consult the 7. Check the general condition of the system including
manufacturer’s instructions for the low water cut-off piping support, joints, etc. Check cleanliness of the
operational check procedure. radiators, baseboard units and/or convectors. Clean
them to the extent possible. If radiators do not heat
4. Check the system to make sure there are no leaks or evenly, vent any remaining air from them.
overfilling problems which might cause excessive
make-up water to be added. Make-up water causes 8. Review operation and User’s Information Manual with
liming in the boiler and brings in oxygen. Oxygen can end-user.
cause severe damage to the boiler though oxygen
corrosion pitting. 9. Hang the Installation, Operation and Maintenance
Manual, User’s Information Manual, and Vent
5. Check the expansion tank and automatic fill valve (if Manufacturer’s Information Manual in an accessible
used) to confirm that they are operating correctly. If position near the boiler.
either of these components causes high pressure in the
system, the boiler relief valve will weep or open,
allowing fresh water to enter the system.

6. Do not allow the system controls to subject the boiler

to excessively low water temperatures, which would
cause condensation of flue gases and corrosion of the
boiler. Operate the boiler at a temperature above 130°F
(54°C). Adjust the boiler limit as required to maintain
boiler temperature above this level.

24
 TROUBLESHOOTING

8. TROUBLESHOOTING
A. SHUT-DOWN CAUSED BY PILOT DANGER
When servicing or replacing items that communicate
OUTAGE, PRESSURE SWITCH OR

with the boiler water, be certain that:

FLAME ROLL-OUT SAFETY
l There is no pressure on the boiler.
SHUT-OFF SWITCH
l The boiler is not hot.

l The power is off.

In the event of a shut-down caused by a pilot outage,
action of the pressure switch or flame roll-out safety shut-
When servicing the gas valve or pilot, be certain that:
off switch effecting a shut-down of the main burners:

l The gas is off.

a. Refer to the Lighting/Operating Instructions in Figure
l The electricity is off.
7.3 to properly turn off the gas to the boiler.
b. Turn off all electric power to the boiler.
c. Call a qualified heating service organization or local gas
company and have the cause of the shut-down WARNING
Do not use this appliance if any part has been under
investigated and corrected.

water. Improper or dangerous operation may result.

d. Refer to Operating Instructions to re-start boiler.

Immediately call a qualified service technician to

inspect the boiler and to replace any part of the
control system and any gas control which has been
B. TROUBLESHOOTING GUIDES
Use Table 8.1 and Figure 8.2 to assist in determining causes under water.
and providing corrective actions to boiler problems. These
guides must be used only by qualified service technicians.
These individuals must follow all applicable codes and
CAUTION
Label all wires prior to disconnection when servicing
regulations in repair of any boiler problems.

controls. Wiring errors can cause improper and

dangerous operation. Verify proper operation after
C. MEASURING SUCTION PRESSURE
Pressure switch requires minimum -0.45" W.C. (-112 Pa) fan servicing.
suction pressure to energize control circuit. Measure when
boiler has been operating at least 15 minutes. See Figure
8.1. CAUTION
Should overheating occur or the gas supply fail to
shut off, do not turn off or disconnect the electrical
supply to the pump. This may aggravate the problem
and increase the likelihood of boiler damage. Instead,
shut off the gas supply at a location external to the
appliance.

Figure 8.1: Measuring Fan Suction Pressure

25
TROUBLESHOOTING

Table 8.1: Boiler Troubleshooting Guide (Burners Functioning)

Problem Possible Causes Corrective Actions

Burners not functioning, 1. Flame rollout switch open. 1. Replace switch. Locate cause and correct.
blower running. 2. Pressure switch in closed position. 2a. Check for plugged or damaged switch tubing.
2b. See Section “Measuring Suction Pressure” in boiler manual. If
adequate, replace pressure switch. If inadequate, check
for blockage or leak in vent system. If ok, replace blower.
3. Ignition system problem. 3a. See ignition system troubleshooting guide below.
3b. See ignition system manufacturer literature for instructions
including key to control LED lamp diagnostics.
Burners not functioning, 1. No power. 1. Check line voltage wiring and fuses.
blower not running. 2. Water Temperature below calculated setpoint 2a. Wait for calculated setpoint to rise / boiler temperature
minus differential. to fall.
2b. Adjust efficiency/economy setting. See limit control
manufacturer’s literature.
3. Limit Control not working. 3. Check wiring and contacts, relay, temperature setting.
Clean and adjust as necessary.

Burners will not shut down. 1. Defective gas valve. 1. See ignition system troubleshooting guide below
to troubleshoot gas valve. Replace if necessary.
2. Short circuit. 2. Check and correct wiring.
Flashback or burning at 1. Manifold gas pressure too low. 1. Adjust to proper pressure.
orifice spuds. 2. Improperly sized/drilled orifice spuds. 2. Install correct spuds.
3. Leaking gas valve. 3. Replace valve.
4. Burrs on orifice. 4. Remove burrs.
5. Low supply gas pressure. 5. Contact gas supplier if natural gas.
6. Draft problems in boiler room. 6. Check air supply, ventilation and venting system.
Delayed ignition. 1. Insufficient pilot flame. 1. Increase pilot gas flow.
2. Pilot burner/orifice clogged. 2. Clean pilot burner and orifice.
3. Overfiring. 3. Reduce rate to input on rating label.
4. Misaligned burners or pilot. 4. Realign burners or pilot.
5. Draft problem in boiler room. 5. Check air supply, ventilation and venting system.
Boiler not heating 1. Underfiring. 1. Increase rate to input on rating label.
properly. 2. Limit set too low. 2. Reset Aquastat to higher setting.
3. Air in system. 3. Vent air from all points in system.
4. Circulator malfunctioning. 4. Check circulator, replace if necessary.
5. Circulation system clogged. 5. Shut down and cool boiler, drain and flush system.
6. Incorrect thermostat heat anticipator setting. 6. Adjust heat anticipator.
Fumes or gas odors. 1. Leaks in gas piping or fittings. 1. Locate and repair or replace.
2. Leaks in gas service line or meter. 2. Shut down boiler and notify gas provider.
3. Obstructed flueways or vent. 3. Clean flueways or vent and remove obstructions.
4. Draft problem in boiler room. 4. Check air supply, ventilation and venting system.
5. Overfiring. 5. Reduce rate to input on rating label.

26
 TROUBLESHOOTING

START
BEFORE TROUBLESHOOTING,
FAMILIARIZE YOURSELF WITH NOTE: “CALL FOR HEAT” 24 VAC SUPPLY IS CONNECTED TO THE 24 V TERMINAL ON THE CONTROL.
THE STARTUP AND
CHECKOUT PROCEDURES.

TURN GAS SUPPLY OFF,

TURN THERMOSTAT
(CONTROLLER) TO
“CALL FOR HEAT.”

POWER TO CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING ALSO.
MODULE? (24 V NO CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM (IF USED) AND THAT THE VENT DAMPER END SWITCH (IF USED)
NOMINAL) IS MADE.

YES

NO PULL IGNITION LEAD AND SPARK OK? NO REPLACE MODULE

CHECK SPARK AT MODULE.
SPARK
ACROSS
IGNITER/
SENSOR YES
GAP?

CHECK IGNITION CABLE, GROUND WIRING, CERAMIC INSULATOR, AND SPARK GAP ARE CORRECT.
YES CHECK BOOT OF THE IGNITION CABLE FOR SIGNS OF MELTING OR BUCKLING, TAKE PROTECTIVE ACTION TO SHIELD CABLE
AND BOOT FROM EXCESSIVE TEMPERATURES.
TURN GAS SUPPLY
ON AND RECYCLE
“CALL FOR HEAT.”

CHECK THAT ALL MANUAL GAS VALVES ARE OPEN, SUPPLY TUBING AND PRESSURES ARE GOOD, AND PILOT BURNER
ORIFICE IS NOT BLOCKED (PILOT GAS FLOWING).
PILOT BURNER NO CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND PILOT OPERATOR ON GAS CONTROL.
LIGHTS? CHECK FOR 24 VAC ACROSS PV-MV/PV TERMINALS ON MODULE. IF VOLTAGE IS OKAY, REPLACE GAS CONTROL.
IF NOT, REPLACE MODULE.
NOTE: IT MAY BE NECESSARY TO RECYCLE THE ‘CALL FOR HEAT” MORE THAN ONCE TO CLEAR THE PILOT SUPPLY TUBES OF AIR.

YES

NOTE: IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY, RESET THE “CALL FOR HEAT.”
CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE.
SPARK CLEAN FLAME ROD.
STOPS WHEN NO CHECK ELECTRICAL CONNECTIONS BETWEEN FLAME ROD AND MODULE.
PILOT IS CHECK FOR CRACKED CERAMIC FLAME ROD INSULATOR.
LIT? CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE.
ADJUST PILOT FLAME.
IF PROBLEM PERSISTS REPLACE MODULE.

YES

CHECK FOR 24 VAC ACROSS PV-MV/PV TERMINALS ON MODULE. IF NO VOLTAGE, REPLACE MODULE.
MAIN BURNER NO CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND GAS CONTROL INCLUDING SAFETY CONTROLS WIRED IN THE CIRCUIT.
LIGHTS?
IF OKAY, REPLACE GAS CONTROL.

YES

NOTE: IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY, RESET THE “CALL FOR HEAT.”
CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE.
NOTE: IF GROUND IS POOR OR ERRATIC, SHUTDOWNS MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL
SYSTEM AT THE TIME OF CHECKOUT.
RUNS UNTIL “CALL NO CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE, PILOT FLAME MUST NOT BE MOVING AROUND DUE TO
FOR HEAT” OUTSIDE AIR FLOWS, ETC.
ENDS? ADJUST PILOT FLAME. CHECK GAS PRESSURE MEETS APPLIANCE SPECIFICATIONS WHILE APPLIANCE MAIN BURNER ON AND ALL
OTHER GAS APPLIANCES ON THE SUPPLY ARE OPERATING AT FULL RATE.
IF CHECKS ARE OKAY, REPLACE MODULE.
YES

“CALL FOR HEAT” ENDS

SYSTEM CHECK FOR PROPER THERMOSTAT (CONTROLLER) OPERATION.

SHUTS NO REMOVE MV LEAD AT MODULE, IF VALVE CLOSES, RECHECK TEMPERATURE CONTROLLER AND WIRING. IF NOT, REPLACE
OFF? GAS CONTROL.

YES

REPEAT PROCEDURE UNTIL

TROUBLE FREE OPERATION
IS OBTAINED.

Figure 8.2: Intermittent Ignition System Troubleshooting Sequence

27
MAINTENANCE

9. MAINTENANCE
WARNING
Product Safety Information
Refractory Ceramic Fiber Product

This appliance contains materials made from refractory ceramic fibers (RCF). Airborne RCF,
when inhaled, have been classified by the International Agency for Research on Cancer
(IARC), as a possible carcinogen to humans. After the RCF materials have been exposed to
temperatures above 1800°F (980°C), they can change into crystalline silica, which has been
classified by the IARC as carcinogenic to humans. If particles become airborne during serv-
ice or repair, inhalation of these particles may be hazardous to your health.

Avoid Breathing Fiber Particulates and Dust

Suppliers of RCF recommend the following precautions be taken when handling these
materials:

Precautionary Measures:
Provide adequate ventilation.
Wear a NIOSH/MSHA approved respirator.
Wear long sleeved, loose fitting clothing and gloves to prevent skin contact.
Wear eye goggles.
Minimize airborne dust prior to handling and removal by water misting the material and
avoiding unnecessary disturbance of materials.
Wash work clothes separately from others. Rinse washer thoroughly after use.
Discard RCF materials by sealing in an airtight plastic bag.

First Aid Procedures:

Inhalation: If breathing difficulty or irritation occurs, move to a location with fresh clean air.
Seek immediate medical attention if symptoms persist.
Skin Contact: Wash affected area gently with a mild soap and warm water. Seek immediate
medical attention if irritation persists.
Eye Contact: Flush eyes with water for 15 minutes while holding eyelids apart. Do not rub
eyes. Seek immediate medical attention if irritation persists.
Ingestion: Drink 1 to 2 glasses of water. Do not induce vomiting. Seek immediate medical
attention.

28
 MAINTENANCE

A. GENERAL D. MONTHLY (WITH BOILER IN USE)

1. Disconnect this boiler from the gas supply piping 1. Verify condensate drain trap (loop) has sufficient water
during any pressure testing of the gas system. to maintain seal and is not blocked. Fill and/or unblock
as necessary.
2. Check pipes adjacent to cold walls or in unheated
spaces. Insulate and tape them if necessary to be sure 2. Check boiler room floor drains for proper functioning.
they can’t freeze up. Keeping the water moving at all
times will reduce the likelihood of freezing. See Section 3. Check function of the safety relief valve (monthly
3 for antifreeze instructions. unless specified otherwise by manufacturer) by
performing the following test:
3. If there is considerable foreign matter in the boiler a. Check valve piping to determine that it is properly
water, the boiler should be shut down and allowed to installed and supported.
cool, then drained and thoroughly flushed out. Use the
drain valve at the bottom of the return connection to b. Check boiler operating temperature and pressure.
drain the boiler. Pipe the drain cock to a suitable drain
or containment device if antifreeze is used. Flush the c. Lift the try lever on the safety relief valve to the full
system to remove remaining matter. If there is open position and hold it for at least five seconds
evidence that hard scale has formed on the internal or until clean water is discharged.
surfaces, the boiler should be cleaned by chemical
means as prescribed by a qualified water treatment d. Release the try lever and allow the valve to close. If
specialist. the valve leaks, operate the lever two or three
times to clear the valve seat of foreign matter. It
may take some time to determine if the valve has
B. DAILY (WITH BOILER IN USE) shut completely.
Daily boiler observation can be performed by the owner. If e. If the valve continues to leak, it must be replaced
any potential problems are found, a qualified installer or before the boiler is returned to operation.
service technician/agency must be notified.
f. Check that operating pressure and temperature
1. Remove any combustible materials, gasoline and other have returned to normal.
flammable liquids and substances that generate
flammable vapors from the area where the boiler is g. Check again to confirm that valve has closed
contained. Make certain that the boiler area has ample completely and is not leaking.
air for ventilation and that there are no obstructions to
the free flow of air to and from the boiler.
4. Test low-water cut-off (if used) as described by the
2. Observe general boiler conditions (unusual noises, manufacturer.
vibrations, etc.)
5. Test limit as described in Section 7, “Check-Out
3. Observe operating temperature and pressure on the Procedure.”
combination gauge located on the right side of the
boiler. Boiler pressure should never be higher than 6. Test function of gas safety shut-off features as
5 psi (35 kPa) below the rating shown on the safety described by gas valve and ignition control
relief valve (25 psig [172 kPa] maximum for a 30 psig manufacturer.
[207 kPa] rating, 45 psig [310 kPa] maximum for a 50
psig [345 kPa] rating). The valve rating can be found on DANGER
When servicing or replacing components, be
the top of the safety relief valve (see Figure 3.4 for

absolutely certain that the following conditions are

location of the safety relief valve). Boiler temperature

met:
should never be higher than 250°F (121°C).

l Water, gas and electricity are off.

4. Check for water leaks in boiler and system piping.
l The boiler is at room temperature.

l There is no pressure in the boiler.

5. Smell around the appliance area for gas. If you smell
gas, follow the procedure listed in the Operating
Instructions to shut down appliance in Figure 7.3.

C. WEEKLY (WITH BOILER IN USE) E. ANNUALLY (BEFORE START OF HEATING

SEASON)
1. Flush float-type low-water cut-off (if used) to remove
sediment from the float bowl as stated in the 1. Inspect flueways, burners and vent system. See
manufacturer’s instructions. Figure 9.2.
a. Refer to the Operating Instructions in Figure 7.3 to
properly turn off the gas to the boiler. Turn off all
electrical power to the boiler.

b. Remove jacket removable door, air inlet pipe, air

box cover, and air box diffuser screen.

29
MAINTENANCE

c. Remove burner hitch pin clips. Disconnect pilot r. Examine air box cover seal. Reposition/replace as
tubing at compression elbow. necessary to assure air tight seal.

d. Disconnect pilot harness at gas valve. Gently pull s. Reinstall air box cover.
pilot harness further inside air box to be able to
remove burner with attached pilot. WARNING
Leaks in the vent system will cause products of
e. Remove burners and pilot.
combustion to enter structure (vent system operates
under positive pressure).
f. Brush gas outlet ports lightly using a soft bristle
brush. If extensive corrosion in outlet ports, replace.

g. Examine pilot hood and igniter for corrosion, scale, t. Examine entire vent system for corrosion, support
ceramic cracking. Replace if necessary. and joint integrity. Repair as necessary. Remove any
h. Remove 3" (76 mm) diameter vent pipe at debris inside vent.
condensate elbow or fan outlet. u. Reconnect vent pipe to fan adapter. Reseal using
high-temp silicones as shown in Section 4, Venting,
WARNING Ventilation and Air Inlet.

Soot accumulation indicates boiler malfunction.

Cause of malfunction must be determined and
v. Refer to Operating Instructions in Figure 7.3 to

corrected before returning boiler to service.

properly return the boiler to operation.

2. Check the pilot and main burner flame. See Figure 9.1.
i. Remove top jacket panel, flue collector/fan The pilot should provide a steady flame enveloping
assembly, and flue baffles. 3/8" to 1/2" (1 cm to 1.2 cm) of the flame sensor. If
required, adjust the pilot as stated in the gas valve
j. Examine flueways and flue collector/fan for scale, manufacturer’s instructions. The main burner flame
soot, and loose rust. inner cone should be approximately
1-1/2" (4 cm) high and should have a very sharp, blue
k. If necessary, brush flueways with wire brush and color characteristic.
remove scale and loose rust from flue baffles. If
corroded, replace baffles.

l. Reinstall flue baffles.

m. Examine flue collector blanket seal.

Reposition/replace as necessary to assure air tight
seal between flue collector and heat exchanger.

n. Reinstall flue collector/fan assembly.

o. Reinstall jacket top panel.

p. Reinstall pilot, burners, hitch pin clips. Reconnect

pilot harness to gas valve, gently pulling harness to
length required to reach gas valve. Figure 9.1: Intermittent Pilot and Main
Burner Flame
q. Reinstall air box diffuser.

Figure 9.2: Inspection of Flueways, Burners, and Vent System.

30
 BOILER DIMENSIONS & RATINGS

10. BOILER DIMENSIONS & RATINGS

Figure 10.1: Boiler Views

Table 10.1: Series GVSC Boiler Dimensions

SERIES GVSC BOILER DIMENSIONS
Boiler
Model Jacket Width “A”
Number
GVSC-03 12-1/2" 318 mm
GVSC-04 15-7/8" 403 mm
GVSC-05 19-1/4" 489 mm
GVSC-06 22-5/8" 575 mm

Table 10.2: Series GVSC Boiler Ratings

SERIES GVSC BOILER RATINGS

Series GVSC

DOE Heating Net Ratings Seasonal Efficiency³ Water

Boiler
Input Capacity³ Water¹,² AFUE Content
Model
Number MBH kW MBH kW MBH kW % Gallon Liter
GVSC-03 65 19 56 16 49 14 86.0 4.72 17.87
GVSC-04 90 26 77 23 67 20 85.0 6.00 22.71
GVSC-05 120 35 102 30 89 26 85.0 7.28 27.56
GVSC-06 150 44 128 37 111 32 85.1 8.56 32.40
1 Net water ratings based on an allowance of 1.15.
2 Consult factory before selecting a boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping
systems, etc.
3 Heating Capacity and Annual Fuel Utilization Efficiency (AFUE) ratings are based on U.S. Government test.

31
REPAIR PARTS

11. REPAIR PARTS

REPAIR PARTS
GVSC GAS BOILER
Repair parts are available from your local Smith distributor.
Note: Remember to include the boiler model number and serial number when ordering parts.

Figure 11.1

32
 REPAIR PARTS

Table 11.1: Repair Parts

Quantity Stock
Description
Required Code
Base Assembly – GVSC-03 – 7800
Base Assembly – GVSC-04 – 7801
1
Base Assembly – GVSC-05 – 7802
Base Assembly – GVSC-06 – 7803
Floor Pan – GVSC-03 – 50100
Floor Pan – GVSC-04 – 50101
2
Floor Pan – GVSC-05 – 50102
Floor Pan – GVSC-06 – 50103
Base Rear Panel Assembly – GVSC-03 – PSC2000
Base Rear Panel Assembly – GVSC-04 – PSC2000-1
3
Base Rear Panel Assembly – GVSC-05 – PSC2000-2
Base Rear Panel Assembly – GVSC-06 – PSC2000-3
4 Base Observation Port Cover – 51771
5 Base/Air Box Spacer – 92 2 50152
6 Air Box Right Side – PSC2023
7 Air Box Left Side – PSC2024
Air Box Top/Front Cover – GVSC-03 – 50143
Air Box Top/Front Cover – GVSC-04 – 50144
8
Air Box Top/Front Cover – GVSC-05 – 50145
Air Box Top/Front Cover – GVSC-06 – 50146
Air Box Diffuser Screen – GVSC-03 – PSC2025
Air Box Diffuser Screen – GVSC-04 – PSC2025-1
9
Air Box Diffuser Screen – GVSC-05 – PSC2025-2
Air Box Diffuser Screen – GVSC-06 – PSC2025-3
10 Rope Gasket Seal, Air Box – 50718
11 Flame Rollout Switch, Thermodisc G4AM00_167C – 51587
12 Flame Rollout Switch Bracket – 50136
Steel Burner – GVSC-03 3 51536
Steel Burner – GVSC-04 5 51536
13
Steel Burner – GVSC-05 7 51536
Steel Burner – GVSC-06 9 51536
– Burner with Pilot Bracket – 51535
Orifice, #48, Normal Altitude Natural Gas Only – GVSC-03 4 50894
Orifice, #48, Normal Altitude Natural Gas Only – GVSC-04 6 50894
Orifice, #48, Normal Altitude Natural Gas Only – GVSC-05 8 50894
Orifice, #48, Normal Altitude Natural Gas Only – GVSC-06 10 50894
14
Orifice, #56, Normal Altitude LP Gas Only – GVSC-03 4 50899
Orifice, #56, Normal Altitude LP Gas Only – GVSC-04 6 50899
Orifice, #56, Normal Altitude LP Gas Only – GVSC-05 8 50899
Orifice, #56, Normal Altitude LP Gas Only – GVSC-06 10 50899
Gas Manifold – GVSC-03 – 50121
Gas Manifold – GVSC-04 – 50122
15
Gas Manifold – GVSC-05 – 50123
Gas Manifold – GVSC-06 – 50124

33
REPAIR PARTS

Figure 11.2

34
 REPAIR PARTS

Table 11.2: Repair Parts (see note)

Quantity Stock
Description
Required Code
16 Insulation Blanket, 1/2" x 1.50", Block to Base – 50867
Block – GVSC-03 – 90419
Block – GVSC-04 – 90420
17
Block – GVSC-05 – 90421
Block – GVSC-06 – 90422
Flue Baffle – GVSC-03 2 51584
Flue Baffle – GVSC-04 3 51584
18
Flue Baffle – GVSC-05 4 51584
Flue Baffle – GVSC-06 5 51584
19 Insulation Blanket, 1/2" x .75", Flue Collector to Block – 50866
Flue Collector – GVSC-03 – 50171
Flue Collector – GVSC-04 – 50172
20
Flue Collector – GVSC-05 – 50173
Flue Collector – GVSC-06 – 50174
21 Gasket, Orifice Plate 2 50135
Orifice Plate, Normal Altitude Natural Gas Models Only – GVSC-03 – PSC5002
Orifice Plate, Normal Altitude Natural Gas Models Only – GVSC-04 – PSC5002-1
Orifice Plate, Normal Altitude Natural Gas Models Only – GVSC-05 – PSC5002-2
Orifice Plate, Normal Altitude Natural Gas Models Only – GVSC-06 – PSC5002-3
22
Orifice Plate, Normal Altitude LP Gas Models Only – GVSC-03 – PSC5003
Orifice Plate, Normal Altitude LP Gas Models Only – GVSC-04 – PSC5003-1
Orifice Plate, Normal Altitude LP Gas Models Only – GVSC-05 – PSC5003-2
Orifice Plate, Normal Altitude LP Gas Models Only – GVSC-06 – PSC5003-3
23 Fan – 50775
24 Fan Adapter – 50200
Jacket – GVSC-03 – 90729
Jacket – GVSC-04 – 90730
25
Jacket – GVSC-05 – 90731
Jacket – GVSC-06 – 90732
– Gas Valve, VR8204A2001, Natural Gas Models Only – 50583
– Gas Valve, VR8204A2183, LP Gas Models Only – 50584
– Pressure Switch, Standard Altitude, .46" W.C. GVSC-03 – 50026
– Pressure Switch, Standard Altitude .50” W.C. GVSC-04/05 – 50025
– Pressure Switch, Standard Altitude .42” W.C. GVSC-06 – 50024
– Safety Relief Valve, 30 PSI, Conbraco 10-408-05 – 50501
– Safety Relief Valve, 50 PSI, Watts #350 – 99950
– Temperature-Pressure Gauge – 51774
– Condensate Drain Elbow – 51185
– Outside Stainless Steel Vent Cap – 50139
– Wall Thimble (standard, up to 11-1/2" wall) – 50137
– Wall Thimble 20 (for a wall greater than 11-1/2" to 20") – 90350
– Inside Thimble Cap – 50138
– Inside Thimble Collar – 50158
– Screened Vent Termination – 50130
– Vent Clamp – 51900
– Limit Control, Beckett AquaSmart 7600B – 50335
– Immersion Well, Beckett 7600T – 50341
– Immersion Sensor, Beckett 7600P – 50339
– Limit Control, Hydrolevel HydroStat 3200 – 50334
– Immersion Well, Hydrolevel – 50723
– Ignition Module, Honeywell S8610 – 50672
– Pilot, Nat Gas, Q348A1002 – 50558
– Pilot, LP Gas, Q348A1358 – 51814
– Ignition Cable – 50640
– Relay, 24VAC Coil, DPST – 50726
Blower Gaskets
– Orifice Plate Gaskets 2 50135
– Fan Outlet Gasket – PSC5019
Note: Consult factory for control system repair parts for models with SmartValve ignition system. Furnish vendor part number of control that needs to be replaced
and boiler serial number.
Part numbers may be subject to change without notice.

35
TEL. (413) 562-9631 • FAX (413) 562-3799