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GT INSTALLATION AND OPERATION INSTRUCTIONS Page 11
The following are important rules that must be followed
when constructing the condensate system:
1. Connect the condensate trap to the drain using
1/2 in, 13 mm, silicone, rubber, reinforced nylon, or
PEX tubing. Long runs must be properly pitched
and supported to prevent blockage.
2. Do not use nylon tubing, as it will collapse, blocking
drainage. This could damage the boiler.
3.
Do not seal the opening between the condensate pipe
and the condensate drain pipe, Figure 19. In the event
of a blocked drain the opening will allow the condensate
to overfl ow and prevent the boiler from fl ooding.
4. Never have the drain pipe higher than the hole in the
back cabinet, this will fl ood the boiler.
5. Never allow the drain to freeze or become blocked.
This will cause condensate to fill the combustion
chamber resulting in a no heat condition and damage
to the boiler.
6. NEVER use copper, steel, or galvanized piping in
the construction of the condensate system.
7. When a condensate pump is used or required, select
a pump that is designed for residential furnaces.
GENERAL PLUMBING GUIDELINES
If connecting this boiler to a system containing cast iron
radiation, be sure to add a strainer to the system to trap
any sediment that may dislodge. Failure to do this could
harm the heat exchanger and void the warranty! The
use of non-oxygen barrier radiant tubing is acceptable,
provided that non-ferrous pipe, valves, and fi ttings are
used throughout the entire hydronic system.
CAUTION: All heating system piping must be
installed in accordance with the ANSI/ASME Boiler
and Pressure Vessel Code, Section IV. All applicable
local codes and ordinances must also be followed. If
the boiler is installed above any radiation elements
it must be fitted with a low water cutoff device
installed above the normal boiler water level!
CAUTION: This boiler must have adequate water
flowing through it whenever the burner is on.
Failure to do this will damage the unit and void the
warranty!
CAUTION: All systems must be fl ushed to remove
sediment, flux, filings and other foreign matter.
Use products such as Fernox “Superfl oc” for new
installations and CHR “Central Heating Restorer”
for retrofits. Also add an inhibitor to the system
water to prevent limestone and magnetite deposits
from forming and to protect the boiler from galvanic
corrosion. An inhibitor such as CHP, “Central
Heating Protector” from Fernox is recomended.
If connecting this boiler to a system containing
cast iron radiation, be sure to add a strainer to the
system to trap any sediment that may dislodge.
Failure to do this could harm the heat exchanger
and void the warranty!
The use of non-oxygen barrier radiant tubing is
acceptable, provided that non-ferrous pipe, valves,
and fi ttings are used throughout the entire hydronic
system. Failure to comply with these instructions
will seriously damage the boiler, voiding warranty!
CAUTION: The boiler fittings cannot support any
weight. The plumbing system must be supported by
the building structure. A wrench must be used to
hold the boiler fi ttings when installing the heating
system piping. Failure to do so can seriously
damage the boiler, voiding warranty!
The GT hot water boiler comes from the factory ready
to be piped to the heating system. The boiler must be
used only in a Primary/Secondary pumping system to
avoid cycling problems in systems that have poor fl ow
or heating zones with very small capacities.
CAUTION: A 1
1
⁄
4
in, 32 mm, primary loop system
must be used for GT-150 & 200 models regardless of
the confi guration of the secondary system design.
A 1
1
⁄
2
in, 38 mm, primary loop system must be used
for the GT-400. Failure to properly plumb the boiler
may void the warranty!