Boiler Manual - Weil-McLain

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GV90+ gas-fired water boiler — Boiler ManualContentsHow it works . . . . . . . . . . . . . 2GV90+ Water Boiler . . . . . . . . 3Please read before proceeding . . . 5Prepare boiler location . . . . . . .6Installations must follow these codes: . . . 6High altitude installations. . . . . . . . . . 6Residential garage installation . . . . . . . 7Check orifice plate — replace if necessary 8Install condensate trap. . . . . . . . . . . . 9Install high altitude air pressure switch whenrequired (only above 5,550 feet) . . . . . . 9Rotate the boiler into position . . . . . . 10Perform hydrostatic pressure test. . . . . 11Install water piping . . . . . . . . 12General piping information. . . . . . . . 12Install relief valve . . . . . . . . . . . . . 12Expansion tank. . . . . . . . . . . . . . . 13System water piping methods. . . . . . . 15Circulators . . . . . . . . . . . . . . . . . 15Simplified pipe/circulator selection . . . 15Baseboard system piping — CIRCULATORzoning (primary/secondary) . . . . . . . 16Baseboard system piping — ZONE VALVEzoning (direct connection) . . . . . . . . 16Radiator system piping . . . . . . . . . . 18Single-zone radiant heating or heat pump 19Adjust balancing valves . . . . . . . . . . 19Multi-zone radiant heating system . . . . 20Piping snow melt systems or combinationsnow melt/space heating systems . . . . . 21Water chiller systems . . . . . . . . . . . 22Multiple boiler installations . . . . 23Placing multiple boilers . . . . . . . . . . 23Controlling multiple GV90+ boilers . . . 23Piping multiple GV90+ boilers . . . . . . 23Multiple boiler water piping. . . . 24Easy-Fit® piping installation . . . . . . . 24Venting & air — general . . . . . . 29When removing a boiler from an existingcommon vent system . . . . . . . . . . . 29Existing vent test procedure. . . . . . . . 29Provide combustion air:. . . . . . . . . . 30Vent and air termination options. . . . . 30DIRECT VENT installations . . . . . . . 30DIRECT EXHAUST installations. . . . . 30Combustion air contamination: . . . . . 30Manifolded combustion air option forDIRECT VENT multiple boiler installations31Air manifold sizing . . . . . . . . . . . . 31Commonwealth of Massachusettsinstallations . . . . . . . . . . . . 34Vent termination requirements . . 35DIRECT VENT — Boiler room airopenings . . . . . . . . . . . . . . 36DIRECT VENT — Sidewall with W-Mvent/air plate . . . . . . . . . . . . 37DIRECT VENT — Sidewall with separatepipes. . . . . . . . . . . . . . 39DIRECT VENT — Sidewall with 3”concentric . . . . . . . . . . . . . 41DIRECT VENT — Vertical with separatepipes. . . . . . . . . . . . . . 43DIRECT VENT — Vertical with 3”concentric . . . . . . . . . . . . . 45Concentric termination assembly(sidewall or vertical). . . . . . . . 47Vent and air piping and boiler connections. . . . . . . . . . . . . . 48DIRECT EXHAUST & DIRECT VENT . 48Follow termination instructions . . . . . 48Installing vent and air piping . . . . . . . 48DIRECT EXHAUST ONLY . . . . . . . . 48DIRECT EXHAUST — Boiler room airopenings . . . . . . . . . . . . . . 49Combustion air provision. . . . . . . . . 49Sizing combustion air openings . . . . . 49Special considerations . . . . . . . . . . . 49GV90+ boiler WITHOUT other appliancesin room . . . . . . . . . . . . . . . . . . . 50Air openings . . . . . . . . . . . . . . . . 50GV90+ boiler WITH other appliances inroom . . . . . . . . . . . . . . . . . . . . 50DIRECT EXHAUST — Sidewall . . 51DIRECT EXHAUST — Vertical. . . 53Gas piping . . . . . . . . . . . . . 54Connecting gas supply piping. . . . . . . 54Natural Gas. . . . . . . . . . . . . . . . . 55Propane Gas . . . . . . . . . . . . . . . . 55Wiring . . . . . . . . . . . . . . . 56Field wiring. . . . . . . . . . . . . . . . . 56Start-up. . . . . . . . . . . . . . . 59Freeze protection (when used) . . . . . . 59Clean system to remove sediment . . . . 59Water chemistry . . . . . . . . . . . . . . 59Antifreeze. . . . . . . . . . . . . . . . . . 59Check for gas leaks. . . . . . . . . . . . . 60Fill and test water system . . . . . . . . . 60Verify gas/air orifice plate . . . . . . . . . 61Check thermostat circuit(s) . . . . . . . . 61Inspect/fill condensate system . . . . . . 61Final checks before starting boiler . . . . 62To start the boiler . . . . . . . . . . . . . 62If boiler does not start correctly . . . . . 62Check system and boiler after start-up . . 62Gas valve adjustment — altitude over 5,500feet ONLY . . . . . . . . . . . . . . . . . 62Final checklist . . . . . . . . . . . . . . . 64Annual start-up and general maintenanceschedule . . . . . . . . . . 67Annual start-up . . . . . . . . . . 68Address reported problems . . . . . . . . 68Inspect boiler area . . . . . . . . . . . . . 68Inspect boiler interior . . . . . . . . . . . 68Inspect condensate drain system . . . . . 68Inspect all piping for leaks . . . . . . . . 68Inspect gas piping . . . . . . . . . . . . . 68Inspect the water system. . . . . . . . . . 68Inspect expansion tank . . . . . . . . . . 68Inspect air openings . . . . . . . . . . . . 69Inspect vent system and air piping . . . . 69Inspect boiler heating surfaces . . . . . . 69Inspect recuperator . . . . . . . . . . . . 69Inspect igniter . . . . . . . . . . . . . . . 69Inspect temperature mixing system . . . 70Inspect limit controls and cutoffs. . . . . 70Inspect gauges . . . . . . . . . . . . . . . 70Inspect blower motor . . . . . . . . . . . 70Inspect oiled-bearing circulators . . . . . 70Inspect boiler relief valve . . . . . . . . . 71To complete Annual Start-up, performstartup and checks: . . . . . . . . . . . . 71Review with owner. . . . . . . . . . . . . 71Service & maintenance . . . . . . 72Cleaning boiler heating surfaces . . . . . 72Inspecting and cleaning the recuperator . 73Troubleshooting . . . . . . . . . . 75VERIFY PROPER OPERATION AFTERSERVICING. . . . . . . . . . . . . . . . . 75Before troubleshooting . . . . . . . . . . 75Check the following . . . . . . . . . . . . 75Checking the air pressure switch . . . . . 75Igniter. . . . . . . . . . . . . . . . . . . . 76Gas Valve . . . . . . . . . . . . . . . . . . 76Blower Housing . . . . . . . . . . . . . . 76Thermal fuse . . . . . . . . . . . . . . . . 76Return temperature sensor . . . . . . . . 76IBC (integrated boiler control) . . . . . . 77IBC indicator lights — lockout modes . . 77IBC indicator lights — non-lockout modes77Replacement parts . . . . . . . . 89Dimensions and ratings. . . . . 100NOTES . . . . . . . . . . . . . . 104NOTES . . . . . . . . . . . . . . 106Handling ceramic fiber and fiberglassmaterials. . . . . . . . . . 107Installation and servicecertificate . . . . . . . . . . . . 1084Part number 550-142-054/1211
GV90+ gas-fired water boiler — Boiler ManualPlease read before proceedingHazard definitionsThe following defined terms are used throughout this manual tobring attention to the presence of hazards of various risk levels orto important information concerning the life of the product.Indicates presence of hazards that will cause severepersonal injury, death or substantial property damage.Indicates presence of hazards that can cause severepersonal injury, death or substantial property damage.Indicates presence of hazards that will or can causeminor personal injury or property damage.Indicates special instructions on installation, operationor maintenance that are important but notrelated to personal injury or property damage.Installer— Read all instructions, including thismanual and all other information shipped with theboiler, before installing. Perform steps in the ordergiven.User — This manual is for use only by a qualifiedheating installer/service technician. Refer to User’sInformation Manual for your reference.User — Have this boiler serviced/inspected by aqualified service technician, at least annually.Failure to comply with the above could result insevere personal injury, death or substantial propertydamage.Write in the CP number in the space provided onthe Installation certificate on page 108 if not alreadyshown.When calling or writing about the boiler— Pleasehave the boiler model number from the boiler ratinglabel and the CP number from the boiler jacket.Consider piping and installation when determiningboiler location.Any claims for damage or shortage in shipmentmust be filed immediately against the transportationcompany by the consignee.Commonwealth of MassachusettsWhen the boiler is installed within the Commonwealth of Massachusetts,comply with the following.• This product must be installed by a licensed plumber or gasfitter.• If antifreeze is used, a reduced pressure back-flow preventerdevice shall be used.• If sidewall vent or vent/air is installed, see instructions onpage 34.Failure to adhere to the guidelines on thispage can result in severe personal injury,death or substantial property damage.When servicing boiler —• To avoid electric shock, disconnect electrical supplybefore performing maintenance.• To avoid severe burns, allow boiler to cool beforeperforming maintenance.• This boiler contains ceramic fiber and fiberglassmaterials. Refer to the WARNING and instructionson page 107.Boiler operation —• Do not block flow of combustion or ventilation airto boiler.• Should overheating occur or gas supply fail toshut off, DO NOT turn off or disconnect electricalsupply to circulator. Instead, shut off the gas supplyat a location external to the appliance.• Do not use this boiler if any part has been underwater. Immediately call a qualified service technicianto inspect the boiler and to replace any part ofthe control system and any gas control that has beenunder water.Combustion air —• DO NOT install combustion air intake where thereis a risk of combustion air contamination.Carbon monoxide detector —• For Direct Exhaust units, a carbon monoxide detectoris required in the boiler room. The carbon monoxidedetector must be wired on the same electricalcircuit as the boiler.• For Direct Vent units, a carbon monoxide detectorthat is wired on the same electrical circuit as the boileris strongly recommended.Boiler water —• Thoroughly flush the system (without boiler connected)to remove sediment. The high-efficiency heatexchanger can be damaged by build-up or corrosiondue to sediment.• Do not use petroleum-based cleaning or sealingcompounds in boiler system. Gaskets and seals in thesystem may be damaged. This can result in substantialproperty damage.• Leaks in boiler or piping must be repaired at onceto prevent make-up water. Use this boiler ONLYin a closed-loop system. Continual fresh make-upwater will reduce boiler life. Mineral buildup in heatexchangers reduces heat transfer, overheats the materials,and causes failure. Addition of oxygen carried inby make-up water can cause internal corrosion.• Do not add cold water to hot boiler. Thermal shockcan cause heat exchanger to crack.Freeze protection fluids —• NEVER use automotive or standard glycol antifreeze.Use only freeze-protection fluids made for hydronicsystems. Follow all guidelines given by the antifreezemanufacturer. Thoroughly clean and flush any replacementboiler system that has used glycol beforeinstalling the new boiler.Part number 550-142-054/1211 5
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Boiler Manual - Weil-McLain

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