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Installation and maintenance instructions for gas-fired condensing hot water boilers models: GC-160 GC-160 GC-160 GC-160 GC-160 (Book No. 62403466, Ed. Sep. 2008) ASME certified INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER.
SAFETY INSTRUCTIONS WARNING: If the information in these AVERTISSMENT: Assurez vous de bien instructions is not followed exactly, a fire suivre les instructions données dans or explosion may result causing property cette notice pour réduire au minimum le damage, personal injury or death. risque d’incendie ou d’explosion ou pour éviter tout dommage matériel, toute blessure ou la mort...
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SAFETY INSTRUCTIONS WARNING!!! These instructions must be read prior In the event of a breakdown and/or malfunction of to installation. If the information in these the boiler, turn off the unit and do not make any instructions is not followed exactly, a fire or attempt to repair it.
TABLE OF CONTENTS SAFETY INSTRUCTIONS ..................................2 TABLE OF CONTENTS ................................... 5 1 - INSTALLATION - CODE REQUIREMENTS ............................7 1.1 - National installation legislation ............................... 7 2 - GENERAL INFORMATION .................................. 8 2.1 - Introduction ....................................8 2.2 - Manufacturer .................................... 8 2.3 - Key to symbols used ................................
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TABLE OF CONTENTS 11.1.3 - Filling the heating system ............................. 39 11.1.4 - Filling of the domestic hot water heat exchanger (“45WN and 45WE” models only) .......... 39 11.1.5 – Auto-purging the heating system .......................... 39 11.2 - General warnings concerning gas supply .......................... 40 11.3 - Confirming the boiler’s gas type ............................
1 - INSTALLATION - CODE REQUIREMENTS 1.1 - National installation legislation - The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the latest edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and or CAN/CSA B149.1, Natural Gas and Propane Installation Code.
2 - GENERAL INFORMATION 2.1 - Introduction 2.3 - Key to Congratulations! symbols used You have effectively purchased one of the best boilers on the WARNING!!! Failure to follow these market. indications can causing an Each single part is built, tested and explosion, extensive property assembled, with pride, at the damage, severe personal injury or...
4 - FUNCTION OVERVIEW - 45WE. This boiler is equal to the and future maintenance. 4.1 - Intended use 45WN model, but is intended for Refer to section 5.2 for minimum and functions of outdoor installation. clearance distances from combustible material. the boiler - 45AE.
4 - FUNCTION OVERVIEW 4.3 - A smart and intelligent boiler When connected to an outside sensor (optional), this boiler is designed to always work at the maximum efficiency. It will automatically change the supply temperature in relation with the outdoor temperature. The graph in figure 4 shows an example on how it can work.
4 - FUNCTION OVERVIEW 4.4 - Characteristic curves of heating system’s residual head 45WN and 45WE boilers are fitted with its own specific circulator pump. The residual head at the boiler connections is shown in graph form in figure 5. Figure 5 - Residual Head for heating circuit for models “45WN”...
5 - INSTALLATION - Mounting & gas and water connections 5.1 - Clearances for installation and servicing for models Figure 8 shows the clearances required for installation and servicing. NOTE: Service clearances are not mandatory, but are recommended to ensure ease of service should it be required.
5 - INST ALLA TION - Mounting & gas and water connections 5.4 - Choosing the installation location for 45WE and 45AE models CAUTION!!! The boiler must be installed on a vertical wall constructed to bear its weight or the boiler and building may be damaged.
5 - INST ALLA TION - Mounting & gas and water connections 5.5 - Mounting the boiler Refer to figure 11: place the cardboard template, provided with the boiler, against the wall; ensure that the template is plumb and the screw holes line up with the wall studs;...
5 - INSTALLATION - Mounting & gas and water connections 5.7 - Condensate be connected to the domestic CAUTION!!! The condensate waste disposal system by means of disposal an appropriate trap capable of drainage system is designed to preventing the pressurization of the empty all the condensate produced condensate system and the return WARNING! The condensate trap...
5 - INSTALLATION - Mounting & gas and water connections 5.9 - Supply and 5.11 - Use of glycol Figure 12 illustrates the position of the supply and return pipes. return piping and other Install a metallic mesh filter on the chemicals return pipe to prevent any residue from the system returning to the...
5 - INSTALLATION - Mounting & gas and water connections 5.13 - Gas supply Before installation a thorough internal cleaning of the gas supply piping line should be performed. Figure 12 shows the positioning of the gas connection on the heater. WARNING!!! Check that the type and the pressure of the gas The boiler and its gas connection...
5 - INSTALLATION - Mounting & gas and water connections 5.15 - Suggested piping and wiring connections for the 45WN and 45WE versions Boiler Figure 16 shows the suggested piping and wiring connection for boiler models 45WN and 45WE. All component listed below, except the flue terminal needs to be field supplied.
5 - INSTALLATION - Mounting & gas and water connections 5.16 - Suggested piping and wiring connections for the 45AN and 45AE versions Boiler Figure 17 shows the suggested piping and wiring connections for boiler models 45AN and 45AE. All components listed below, except the flue terminal need to be field supplied.
6 - INSTALLATION - Electrical connections 6.1 - Electrical connections: overview WARNING!!! Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation! ATTENTION!!! Au moment de l’entretien des commandes, étiquetez tous les fils avant de les débrancher.
6 - INSTALLATION - Electrical connections 6.2 - Connecting the power supply cable To connect the electrical power supply cable, follow the steps below while referring to figure 18: remove the boiler casing following the instructions given in section 13.2 or 13.3; press the two plastic springs tabs labeled “B”...
6 - INSTALLATION - Electrical connections route the cable through an empty boiler proceed as follows: then press and release the cable clamp in the junction box remove the boiler casing according button several times until the connect the cable leads to the “RT” to the instructions given in section terminals as shown in figure 18.
6 - INSTALLATION - Electrical connections 6.8 - Installing the remote command on 45WE and 45AE models Install the remote command (item “C” of figure 20) in a site inside the house.To connect the remote command to the boiler, proceed as follows: remove the boiler casing according to the instructions given in section...
7 - INSTALLATION - Indirect storage tank connections 7.1 - Connecting the boiler to an indirect storage tank All boilers listed in this manual , can be connected to an indirect storage tank as follows (the water and electrical connections must be made per figure 21): To make the electrical connections, follow the steps below while refering also to figure disconnect the boiler from the electrical...
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7 - INSTALLATION - Indirect storage tank connections A = front cover of the electrical box B = plastic spring to open the electrical box C = Direction to open the electrical box D = Switches for the functional setting of the boiler Figure 22 - Contro board and junction box board details...
8 - INSTALLATION - Vent & combustion air (d) Place in operation the appliance (c) Dans la mesure du possible, fermer 8.1 - Removing of a being inspected. Follow the lighting toutes les portes et les fenêtres du boiler from a instructions.
8 - INSTALLATION - Vent & combustion air 8.2 - Venting The vent system shall be installed The minimum clearance so as to prevent the accumulation of measurement between two vent end systems condensate. When horizontal vent terminations of this kind of boilers runs exceed 5 ft (1.5m), they must shall be not less than 2 ft (0.6 m).
9 - INSTALLATION - Split 80/80PP venting system 9.1 - “Split 80/80PP” system (polypropylene) or AL29-4C (UL 1738/UL C 636) system NOTE:This vent system is not available for 45WE and 45AE models The boiler is not supplied with the fittings needed for separate vent and combustion air systems.
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9 - INSTALLATION - Split 80/80PP venting system Horizontal vent systems should be as short and straight as possible. The vent system must be both gas tight and watertight. All seams and joints must be joined and sealed in accordance with the vent system manufacturer’s instructions.
9 - INSTALLATION - Split 80/80PP venting system 9.2 - “Split 80/80PP” system components Some of the most commonly used components for installing the “Split 80/80PP” polypropylene vent and combustion air systems are listed below: 62617286 - No. 1 - Split adaptor 80/80 PP 61302011 - No.
9 - INSTALLATION - Split 80/80PP venting system the second example shows the vent WARNING!!! Under no conditions, 9.3 - “Split 80/ system run through a dormant shall this boiler vent gases directly 80PP” system: chimney. Condensation is collected into a masonry chimney, nor can inside the boiler itself.
10 - INSTALLATION - Coaxial 60/100PP venting system 10.1 - “Coaxial 60/ 100PP” polypropylene system The boiler is not supplied with the fittings needed for connecting a coaxial vent/combustion air system. A special kit must be ordered to connect the boiler with the “Coaxial 60/100PP”...
10 - INSTALLATION - Coaxial 60/100PP venting system 10.2 - “Coaxial 60/100 PP” system components The following coaxial polypropylene vent and combustion air system components are available, on request, for installing the “Coaxial 60/100PP” system 62617255 - No. 2 flashing for roofs pitched between 15°...
10 - INSTALLATION - Coaxial 60/100PP venting system 10.3 - “Coaxial 60/ 100PP” system: installation examples When a coaxial vent and combustion air system is installed, figure 32, whether vertical or horizontal, it must be sloped 1/4 in/ft, (21 mm/m) towards the boiler.
11 - OPERATING gauge, item “30” in figure 1, reads 11.1 - Operating 11.1.2 - Filling the 20 psi (1.5 bar) and “FILL” Before starting the boiler, the following condensate trap disappears from the display; must be done. check that there is no water leaking The condensate trap is positioned from the fittings.
11 - OPERATING NATURAL GAS temperature calculated is higher 11.2 - General than the minimum running Maximum supply pressure = 11 warnings temperature as explained in section in.W.C. (27.5 mbar). 12.4. concerning gas Minimum supply pressure = 1.5 If the pump indicator is illuminated, in.W.C.
11 - OPERATING 11.7 - Gas supply At the end of the check, turn the screw in pressure connection “D” in figure 35, pressure checking clockwise until snug and checking for any gas leaks. and adjustment CAUTION!!! Never force the The gas supply pressure must match that listed on the boiler rating label.
11 - OPERATING 11.8 - Check the combustion air pressure The boiler has a factory-set air/gas ratio. The pressure of the gas at the burner is indirectly controlled by the blower. The combustion air pressure is checked inside the boiler and must correspond with that shown in the table in section 14 under the item “combustion air pressure”.
11 - OPERATING for more than 10 seconds, the To adjust the CO2 proceed as follows: 11.9 - Checking and use a screwdriver to turn screw “E” display will show a blinking adjusting CO2 shown in figure 35; turn screw “E” clockwise to reduce press the key until the levels...
11 - OPERATING 11.10 - Adjusting 11.11 - Domestic the heating hot water flow rate capacity adjustment (45WN This boiler has been engineered with and 45WE models an “intelligent” micro-processor control only) that will adjust the heating output to match the system demand. To The volume of domestic hot water that maximize the effectiveness of the the boiler can produce, depends on the...
12 - USE room thermostats are satisfied (see boiler efficiency. It is suitable for the 12.1 - Adjusting the to an appropriate electrical system). following system types: domestic hot water A - small systems, with radiators where the thermostat is installed in a room CAUTION!!! If the boiler is temperature whose temperature is characteristic...
12 - USE proceed to make the appropriate responding to outdoor temperature , the heating service switches adjustments bearing in mind that: changes. A high “Reaction” value back on. If for some reason the heating A - each parameter must be set in results in reaching full running service doesn’t match the load, use small degrees;...
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12 - USE OA = Inclination of the line Ob = Minimum heating temperature Oc = Maximum heating temperature Outside temperature (°C) br = “Fix point” of the angle Outside temperature (°F) fulcrum of the line b = parallel shift of the line (adjusted by the heating knob, item “33”...
12 - USE 12.5 - Boiler switch CAUTION!!! Improper setting settings of these switches could cause the The control board shown in figure 1, boiler to malfunction resulting in item “14”, and figure 22, contains a improper system performance. series of switches that allow the boiler Only a qualified technician, with an to be configured to match the in-depth knowledge of the boilers’...
12 - USE NOTE: If no key is pressed for more 12.10 - “Users’ use the keys, to than 60 seconds, the control menu” change the value of the selected automatically exists the “Users’ parameter. menu”. Any parameter change not When entering the “Users’...
12 - USE 12.11 - “Installers’ menu” CAUTION!!! Changing these parameters could cause the boiler and therefore the system to malfunction. For this reason, only a qualified technician who has in- depth knowledge of the boiler should change them. The boiler’s micro-processor makes this menu of parameters available to the qualified technician for the analysis of the functioning and adjustment of...
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12 - USE The table below lists each “Installers’ menu” parameter, what it affects and its adjustment range. PARAMETER DESCRIPTION INFORMATION ON DISPLAY ITEM “2” OF FIGURE 42 Boiler and heating supply temperature, Value in °F (cannot be changed) measured by U1 sensor Domestic hot water temperature, Value in °F (cannot be changed) measured by U2 sensor...
12 - USE “31” in figure 1, continually 12.12 - shows the operating status of Diagnostics the boiler as shown below (see also section 16): During the normal operation of the boiler, the display item INFORMATION ON DISPLAY ITEM PARAMETER DESCRIPTION “2”...
12 - USE 12.12.1 - Diagnostics: “L” lock-outs Lock-out “L” Checks to make Solutions description Code Check: a-If the gas supply pressure is incorrect, it must be adjusted to No flame detected after a-correct gas supply pressure (see the correct pressure; three ignition attempts.
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12 - USE 12.12.1 - Diagnostics: “L” lock-outs (continued) Lock-out “L” Solutions Controls description Code Program error Replace the power control board Flame sensed for 10 Replace the gas valve, or replace the power control board seconds, after the closure of the gas valve Flame sensed before Replace the gas valve, or replace the power control board...
12 - USE 12.12.2 - Diagnostics: “E” blocking errors Blocking “E” Checks to make Solutions description Code If the sensor resistance does not correspond, it must be U1 boiler temperature Check that the electrical resistance of replaced; sensor circuit interrupted. the sensor corresponds with the graph if the electrical circuit is damaged, it must be repaired;...
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12 - USE 12.12.2 - Diagnostics: “E” blocking errors (continued) Blocking “E” Checks to make Solutions description Code If the sensor resistance does not correspond, it must be U8 return temperature Check that the electrical resistance of replaced; sensor short-circuited the sensor corresponds with the graph if the electrical circuit is damaged, it must be repaired;...
12 - USE 12.13 - Remote command for model 45WE and 45AE Because the 45WE and 45AE boilers are intended also for outdoor installation, they are supplied with a remote commad that can help you to drive the boiler from inside building. Heating and domestic temperature regulation and reset of the boiler, may be performed directly on the remote...
13 - MAINTENANCE 13.1 - General precaution WARNING!!! Never store combustible materials, gasoline or any product containing flammable vapors and liquids in the vicinity of the boiler. Failure to comply with this warning can result in extensive property damage, severe personal injury or death! WARNING!!! Never obstruct the flow of combustion and ventilation air.
13 - MAINTENANCE 13.2 - Removing the casing for models 45WN and 45AN In order to remove the casing, follow the steps below while refering to figure remove screws “A”; raise latch “C”; remove the front cover; press the two plastic springs, item “L”, down;...
13.3 - Removing the plastic cover on a 45WE and 45AE boilers In order to remove the casing, follow the steps below while refering to figure remove screw “E”; push upward, with your hands, in the points indicated by “Q” and “R”; pull-out all the cover press the two plastic springs, item “L”, down;...
13 - MAINTENANCE protect the gas valve outlet, from WARNING!!! while performing the 13.4 - Cleaning the entering any object or condensing next step, carefully wash only the burner and primary water; inside of the combustion chamber remove the entire fan - burner “H”...
13 - MAINTENANCE 13.5 - Correct positioning of the ignition and flame detection electrodes For the boiler to work properly the electrodes must be positioned as shown in figure 47: the distance between the ignition electrodes “A” and “B”, must be between 0.08 in (2 mm), and 0.082 in (2.5 mm);...
13 - MAINTENANCE 13.7 - Condensate trap cleaning The condensate trap must be cleaned every year. Follow the steps below to properly clean the condensate trap and its associated components while refering to figure 48: run the fan as described in section 13.13.2, to minimize the amount of liquid present in the trap, item “A”;...
13 - MAINTENANCE 13.8 - Circulator pump motor replacement (only for 45WN and 45WE models) To replace the circulator pump follow the steps below while, refering to figure follow the steps in section 13.11 to isolate and drain the water from the boiler;...
13 - MAINTENANCE 13.10 - 3-way valve removal (only for 45WN and 45WE models) The 3-way valve, detail “F” in figure 51, directs hot water produced by the primary heat exchanger to the heating circuit or to the secondary heat exchanger for the production of d.h.w.
13 - MAINTENANCE 13.11 - Draining the open all the hot and cold faucets in press the keys the building; heating side of the together for more than 10 seconds, if there isn’t a faucet or drain valve below the boiler level, disconnect until a blinking appears on the boiler...
13 - MAINTENANCE 13.14 - Water and flue temperature sensor The boiler has a number of sensors that measure temperature. The electrical resistance between the sensor wires must correspond with the values shown in figure 53. The temperature sensors are: U1; U2, U3, U5, U6, U7 and U8.
13 - MAINTENANCE 13.16 - Functional wiring diagram WARNING!!! Label all wires prior to disconnection ATTENTION!!! Au moment de l’entretien des when servicing controls. Wiring errors can cause commandes, étiquetez tous les fils avant de les improper and dangerous operation! Verify proper débrancher.
13 - MAINTENANCE 13.17 - Multiwire wiring diagram LEGEND TO FUNCTIONAL AND MULTIWIRE DIAGRAM WARNING!!! Label all wires prior to ATTENTION!!! Au moment de l’entretien disconnection when servicing controls. des commandes, étiquetez tous les fils ALA - Alarm output Wiring errors can cause improper and avant de les débrancher.
14 - TECHNICAL DATA MODEL 45WN, 45AN, 45WE and 45AE Country of destination USA and Canada Type of boiler Direct Vent boiler Category of discharge chimney CSA certificate N° 2045300 (114696) Maximum Heat input Btu/hr 160,000 Minimum heat input Btu/hr 30,000 Efficiency at maximum heat input (160°F/140°F) Maximum Heat output (160°F/140°F)
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16 - MENU’S FLOW CHART To enter this menu you must: shut Off the main electrical supply; CAUTION!!! Changing these move the switch n° 7 (see figure 22, parameters could cause the boiler item “D”) to the ON position; and therefore the system to lite On the main electrical supply.
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COSMOGAS srl Via L. da Vinci 16 47014 - Meldola (FC) ITALY www.cosmogas.com info@cosmogas.com Spare parts are available from your local authorized wholesale distributor. For a location of the one nearest you call 413-564-9538.
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