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Read carefully prior to installation and maintenance.

Installation and Service Instructions

Gas boiler

LoganoUS/CA GC 144 II

6 720 804 440-00.2T

6 720 808 893 (2017/02) US/CA

WARNING!
Installation, adjustment, modification, opera-
tion or maintenance of the heating system
carried out by unqualified personnel may
result in property damage, personal injury,
and loss of life.
The directions of this installation and main-
tenance manual must be followed precisely.
Contact a qualified service company, service
provider or the gas company if support or
additional information is required.

CAUTION!
Before placing this boiler in operation
observe the safety instructions of this installa-
tion and maintenance manual.

CAUTION!
The operating manual is a component of the
technical documentation handed over to the
operator of the heating system. Discuss the
instructions in this manual with the owner or
operator of the heating system and ensure
that they are familiar with all information
required for operation of the heating system.

Keep this installation and maintenance
manual available for future reference.

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Содержание GC144/3

Страница 1: ...wed precisely Contact a qualified service company service provider or the gas company if support or additional information is required CAUTION Before placing this boiler in operation observethesafetyinstructionsofthisinstalla tion and maintenance manual CAUTION The operating manual is a component of the technical documentation handed over to the operator of the heating system Discuss the instructi...

Страница 2: ...ings for combustion air supply and venting 12 9 Requirements for connection to chimneys or venting systems 13 10 Flue pipe installation 13 11 Placing the heating system in operation 14 11 1 Starting up the GC 144 II 15 11 1 1 Prepare pressure measurement 15 11 1 2 Turning on heating system 16 12 Final start up procedures 16 13 Start up protocol 19 14 Taking the heating system out of operation 20 1...

Страница 3: ...entilation or combustion air availability may cause dangerous flue gas leaks or formation Make sure that inlets and outlets are not reduced in size or closed If faults are not corrected immediately the boiler must not be operated until all faults have been corrected Inform the system operator and or owner of the fault and the danger in writing Whenworkingonthefluegasventingequipmentorventdamperlea...

Страница 4: ... Gas Code ANSI Z 223 1 If specified by the local regulatory authorities the heating system must comply with the regulations of the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 Carbon monoxide detectors must be installed as specified by the local regulations The boiler must be serviced annually chapter 15 page 20 2 3 Boiler Operating Conditions The hot wa...

Страница 5: ...oiler 2 3 8 RK 1 VK 1 GAS EL GAS 6 720 804 440 02 1T Boiler size Boilerinput A B Vent connection II Min relief valve capacity Number of Orifices Water volume Dry weight Btu hr Inches Inches Inches lb hr Qty US Gal lbs 18 3 74000 13 1 8 8 5 62 2 2 4 228 25 4 103000 16 3 4 8 2 3 5 86 3 2 9 287 32 5 132500 20 3 8 9 1 2 6 110 4 3 4 349 5 Table 3 Dimensions specs for GC 144 II For the size and dimensio...

Страница 6: ...iler cart Move boiler to desired location Component Qty Packaging method Boiler complete 1 1 palette B kit components 1 1 4 supply manifold 30 psi relief valve long shank boiler drain pressure temperature gauge 90 elbow 1 x 1 NPT 90 elbow 1 x 1 NPT 90 elbow NPT nipple nipple1 NPT nipple 1 NPT 1 1 cardboard box1 1 On Palette Vent damper 1 1 cardboard box1 Circulator 1 1 cardboard box1 Technical doc...

Страница 7: ...ed on a flammable base but not on carpet Fig 7 Required clearances in the boiler room 1 Recommended service clearances 2 Required minimum clearances 3 Burner tray access door with combustion air opening as required per ANSI Z 223 1 6 2 Leveling the boiler Level the boiler in both horizontal directions Level the boiler using a level and place small wedges not supplied for leveling purposes 7 Boiler...

Страница 8: ... low water cut off must be installed during installation of the boiler and placed above the water level in the boiler without any means of shutting the water off between the boiler and low water cut off figure 8 NOTICE System damage due to high temperature variations in the heating system If the boiler is operated in connection with a refrigerationsystem makesurethatthepipesforthe refrigerated liq...

Страница 9: ...boiler must be grounded as specified by the regulations of the relevant local authorities otherwise follow the regulations of the National Electrical Code ANSI NFPA 70 The boiler is fully functional with the factory installed aquastat and the field installed vent damper and heating system circulation pump Power supply connection Install incoming power to the boiler per local and state codes Instal...

Страница 10: ...er jacket if required by the local code We recommend installing a manual shut off valve in the main gas pipe to the boiler The gas pipe must be fastened outside the boiler The local codes must be observed during installation of the gas piping connections otherwise the regulations of the National Fuel Gas Code ANSI Z 223 1 must be followed Install gas piping without any undue stress on the piping T...

Страница 11: ...feed water connection Open automatic vents slightly to allow the air to escape Slowly fill heating system Observe pressure display on pressure gauge during this process Check connections and pipes for leaks Bleed heating system through the bleed valves on the radiators or other air elimination components or high points in the system If the pressure drops during air bleeding water must be added Ins...

Страница 12: ...om the outer edge of the opening The shortest dimension of all inlet and outlet openings must not be less than three inches Total air supply from outside the building Make sure that the boiler room has two permanent openings one of which must not be more than 12 inches from the ceiling and the other must not be more than 12 inches from the floor of the boiler room calculated from the outer edge of...

Страница 13: ...ain turned off All unused openings of the common system must be sealed Inspect the venting system to ensure that it has the correct dimensionsandlongitudinalinclination Makesurethatthesystemis not blocked leaking corroded or has any other faults that cause it to operate improperly Ifnecessary closealldoorsandwindowsinthebuildingandalldoors between the space in which the heating systems that remain...

Страница 14: ...1 Placing the heating system in operation The burner and gas train integrated in the boiler have been tested at the factory as described in ANSI Z 21 13 to ensure safe operation of the heating system and verify specific performance indicators Preparing for operation Set the room thermostat optional to the lowest setting 4 3 2 1 5 6 7 6 720 804 440 16 1T 1 2 6 720 804 440 17 2T All connection point...

Страница 15: ...mentporton the gas valve Install pressure measuring nipple and attach a pressure gauge to measure the orifice pressure Open gas shut off Fig 20 Gas valve 1 ON OFF knob shown in ON position 2 Screw plug for gas pressure measurement port 3 Screw plug for orifice measurement port 4 Ignition gas line connection Main gas orifice identification Boiler size 18 25 32 Natural gas 285 275 270 LP 180 175 170...

Страница 16: ... Fig 23 Gas valve 1 ON OFF knob shown in ON position Checking gas supply pressure Check the gas supply pressure while the boiler is operating The connectionpressurefornaturalgasmustbebetween4 7 and10 5 W C For propane gas LP it must be between 11 and 13 W C If thegaspressureisinthecorrectrange recordthemeasuredvaluein the start up protocol then continue with the next step If the supply pressuredoe...

Страница 17: ...s shut off The main burner flame figure 25 and the ignition flame are extinguished After no more than six 6 seconds the main gas solenoid valve on the gas valve must close with an audible noise If the gas valve does not operate correctly turn ON OFF knob on the gas valve clockwise to the OFF positionimmediately Closethemaingasshut offanddisconnectthe heating system from the main power source and c...

Страница 18: ...OFFposition Disconnectthe heating system from the power source and turn thermostat to its lowest setting Seal leaks Repeat all steps in this paragraph Carefully wipe away the soapy water to prevent corrosion caused by the alkaline content of the soap Check the position of the vent damper The damper must be fully open vertical When burner is on flue gases must not escape from the vent hood Fig 27 C...

Страница 19: ...tion Start up procedure Remarks or measured values 1 Type of gas Natural gas LP 2 Has the leak test been completed 3 Check combustion air inlet and outlet openings and flue gas connection 4 Check the equipment correct orifices See below and convert gas type if necessary 5 Fill boiler with water and bleed complete heating system 6 Measure gas supply pressure flow pressure inches W C 7 Measure manif...

Страница 20: ... 15 2 Testingthefluesystem includingcombustionair air inlets and Ventilation openings Check the venting system including the combustion air inlet and outlet openings All faults must be repaired immediately Make sure that the combustion air feed and the inlets and outlets are not blocked at any point 15 3 Inspection of the boiler and burner Visually check the boiler and burner for external dirt If ...

Страница 21: ...1 Flame rises to 1 above sensor 2 Ignition flame Remove the safety screw on the adjustment screw for the igniter figure 24 page 17 Turn the inner adjustment screw clockwise to reduce the size of the ignition flame and counterclockwise to increase it After completed adjustment replace the safety screw figure 24 page 17 If the flame is too small the pilot orifice needs cleaning figure 39 page 23 If ...

Страница 22: ... 1 Screw nuts two 2 Screws on gas manifold on top of gas valve four Remove four 4 screws from gas manifold on top of gas valve Remove two 2 screw nuts on burner tray and take out the tray Fig 36 Remove top cover Remove 4 screws on sides of the top cover and lift off Remove top boiler insulation Unscrew cleaning cover from the venting manifold Cover control with foil to prevent entry of metal dust ...

Страница 23: ...ontinue to ventilate boiler room well Install burner Reattach boiler jacket Fig 37 Clean out the gas passages 1 Cleaning brush 2 Insulation 3 Foil Fig 38 Wet cleaning boiler 15 6 Cleaning the burner Remove burner chapter 15 5 1 page 22 Check burner rods for dirt If necessary clean burner as described below Unscrew ignition burner unit from burner Disconnect ignition gas line from ignition burner u...

Страница 24: ...g final checks Placeboilerinoperationasdirectedin Placingtheheatingsystemin operation chapter 11 page 14 Follow instructions in Final start up procedures Test low water alarm Check area around boiler for hazards Completethemaintenanceprotocoltoconfirmthatallmaintenacework has been conducted Sign the maintenance protocol and discuss it with the owner of the heating system Be careful not to damage t...

Страница 25: ...er page 20 4 Cleaning of boiler page 21 5 Cleaning of burner page 23 6 Measuring gas supply pressure page 16 inches W C inches W C 7 Measuring orifice pressure page 16 inches W C inches W C 8 Checking for leaks in operating condition page 14 9 Checking pilot burner flame page 21 ff 10 Checking main burner flame page 16 11 Check the vent damper page 18 12 Check high temperature limit control page 1...

Страница 26: ...and maintenance Logano GC 144 II 6 720 808 893 2017 02 26 Date Date Date Date Date inches W C inches W C inches W C inches W C inches W C inches W C inches W C inches W C inches W C inches W C Table 13 Maintenance protocol ...

Страница 27: ...ssembly You can t get the If everything is OK replace pilot assembly No Heat requirement ended system switches off flue baffle closes End of troubleshooting Repeat procedure until heating system operates properly On models with vent damper check that it operates and limit switches are present If necessary replace vent damper Check ignition wiring ceramic insulator of ignition electrode and ignitio...

Страница 28: ...ignition flame Specified thermostat value control reached Main and ignition gas valves close gas burners ex tinguished vent damper if installed closes Ignition burner operation Ignition flame burns automatic ignition signals steady ignition flame or ignition flame does not burn pilot assembly starts ignition at tempt switches off after 90 seconds END PHASE 1 Ignition attempt PHASE 2 Main burner op...

Страница 29: ...y valid in the U S A and only for elevations from 0 8500 ft Boiler size Number of orifices Main gas orifice identification for elevations from feet in ft3 h inch W C 0 8500 ft 1 1 installation attitude 18 3 2 180 29 6 8 8 25 4 3 175 41 2 8 6 32 5 4 170 53 8 7 Table 15 Main gas orifice identification and manifold pressure for Natural gas at 60 F 30 inch HG These values are only valid in the U S A a...

Страница 30: ... orange yellow black 4 R W L2 Plug Plug PV Intermittent pilot control module S8600H Connecting terminals for thermostat 2 Burner assembly Terminals on boiler block Main supply power use circuit breaker as required by code 1 Intermittent pilot dual valve combination gas control VR8204 Pilot burner Honeywell Main valve Pilot valve green blue white red GND MV MV PV GND PV MV PV MV 24V 24V 3 2 1 yello...

Страница 31: ...Burner Spark Gas valve Main Pilot PV PV MV GND MV S8600H GND PV PV MV MV 24V 24VGND K1 TR High Limit Flame roll out safety shutoff switch K2 B2 L2 N L 24V AWG 18 WIRE 120 VAC Wiring Schematic GC 124 GC 144 Wire nut Wire nut Wire nut Circuit breaker Emergency shut off switch Fuse 1 25AT Page 2 2 Wiring diagram gas boiler GC124 USA GC 144 USA Intermittent ignition 8469 8718588198 2012 11 GAW 032 USA...

Страница 32: ......

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