Boiler Manual - Weil-McLain

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GV90+ gas-fired water boiler — Boiler ManualStart-up (continued)Check for gas leaksBefore starting the boiler, and during initial operation,use a leak detector or smell near the floor andaround the boiler for gas odorant or any unusualodor. Remove boiler front door and smell interiorof boiler enclosure. Do not proceed with startupif there is any indication of a gas leak. Repair anyleak at once.DO NOT adjust or attempt to measure gas valveoutlet pressure except where instructed specificallyin this manual. This setting is suitable fornatural gas and propane, requiring no field adjustment.Attempting to alter or measure the gasvalve outlet pressure without following the correctprocedures could result in damage to the valve,causing potential severe personal injury, death orsubstantial property damage.Propane boilers only — Your propane suppliermixes an odorant with the propane to make itspresence detectable. In some instances, the odorantcan fade, and the gas may no longer have anodor. Before startup (and periodically thereafter),have the propane supplier verify the correct odorantlevel in the gas.2. See Replacement parts at the end of this manual for Weil-McLainpart numbers to obtain antifreeze through a Weil-McLain distributor.Use the correct amount of antifreeze1. Determine the freezing temperature needed (to protect againstlowest likely temperature the system water will encounter).2. Find the antifreeze concentration by volume needed for this temperaturefrom the antifreeze manufacturer’s data on the antifreezecontainer.3. Add up the volume (gallons) of all system piping and components,including the expansion tank and boiler.a. Boiler water content is listed in Figure 109, page 101.b. Remember to include expansion tank water content.4. Multiply this volume by the (percent) antifreeze needed to find thenumber of gallons of antifreeze to add.Fill and test water system1. Fill system only after ensuring the water meets the requirementsof this manual.Purge air from water system1. Connect a hose to the purge valve (see purge/drain valves in pipingdiagrams beginning with Figure 17, page 16. Route hose to an areawhere water can drain and be seen.2. Close the boiler or system isolation valve between thepurge valve and fill connection to the system.3. Close zone isolation valves.4. Open quick-fill valve on cold water make-up line.5. Open purge valve.6. One zone at a time, open the isolation valves. Allowwater to run through the zone, pushing out the air. Rununtil no noticeable air flow is present. Close the zoneisolation valves and proceed with the next zone. Followthis procedure until all zones are purged.7. Close the quick-fill water valve and purge valve andremove the hose. Open all isolation valves. Watch thatsystem pressure rises to correct cold-fill pressure.8. After the system has operated for a while, eliminateany residual air by using the manual air vents locatedthroughout the system.9. If purge valves are not installed in system, open manualair vents in system one at a time, beginning with lowestfloor. Close vent when water squirts out. Repeat withremaining vents.10. Open automatic air vent (diaphragm-type or bladdertypeexpansion tank systems only) one turn.11. Starting on the lowest floor, open air vents one at a timeuntil water squirts out.12. Repeat with remaining vents.Pressurize system1. Close manual and automatic air vents and boiler drainvalve.2. Fill system to correct system pressure. Correct pressurewill vary with each application.a. Typical cold water fill pressure for a residentialsystem is 12 psi (when using a 30 PSIG boiler reliefvalve).b. Pressure will rise when boiler is turned on and systemwater temperature increases. Operating pressuremust never exceed 5 PSIG less than the boiler reliefvalve setting.3. At initial fill and during boiler startup and testing, checksystem thoroughly for any leaks. Repair all leaks beforeproceeding further.Eliminate all system leaks. Continual freshmake-up water will reduce boiler life. Mineralscan build up in sections, reducing heat transfer,overheating heat exchanger, and causingheat exchanger failure.Use inhibitor supplied with boiler1. The GV90+ boiler is shipped with Sentinel X100 inhibitorand Sentinel inhibitor test kit. See Replacement partsat the end of this manual for re-ordering information.2. After filling the system as directed in these instructions,use a caulking gun to inject the X100 inhibitor into thesystem, following the instructions on the tube.60Part number 550-142-054/1211
GV90+ gas-fired water boiler — Boiler ManualStart-up (continued)3. Inject all of the inhibitor supplied with the boiler. Allow time forthe water to circulate and mix. Then check the inhibitor level. Addadditional inhibitor if necessary.Check/verify water chemistry1. The system may have residual substances that could affect waterchemistry.2. After the system has been filled and leak tested, verify water pHand chlorine concentrations are acceptable.3. Verify antifreeze concentration, when used.4. Follow the instructions on the Sentinel test kit to sample the systemwater and verify inhibitor concentration.Check inhibitor concentration annually1. Test the pH of a sample of system water at least annually. The pHof the water mixture must be between 7.0 and 8.5. (Or use theSentinel inhibitor test kit to check concentration.)2. If pH is outside this range (or inhibitor test kit indicates low level),the inhibitor level may not be sufficient to prevent corrosion.3. Test antifreeze concentration.Test antifreeze concentration at least annually. If concentrationis low, add antifreeze or drain system and refillwith correct mixture.4. Follow instructions on antifreeze container to determine theamount of antifreeze needed. DO NOT exceed 50% by volumeconcentration of antifreeze.5. Check inhibitor level after adjustments are made.Verify gas/air orifice plateThe proper orifice plate must be used. Failure to doso will cause severe personal injury, death or substantialproperty damage.1. Remove the jacket front panel.2. Read the boiler size written on the gas/air orifice label tab, verifyingthe correct size. See Figure 5, page 8 for details.3. The orifice plate must be plain aluminum for natural gas. Forpropane gas, the exposed tab of the plate should be red.4. Replace the orifice plate if necessary, following the guidelines onpage 8.5. Once the external thermostat circuit wiring is checkedand corrected if necessary, reconnect the external thermostatcircuit wires. Allow the boiler to cycle.Inspect/fill condensate systemInspect/check condensate lines and fittings1. Inspect the condensate drain line, condensate PVC fittingsand condensate trap.Fill condensate trap with water1. Loosen the hose clamp (Figure 70, item 2) that securesthe condensate trap (Figure 70, item 1) to the bottomof the recuperator (Figure 70, item 3).2. Pull the condensate trap tube off of the recuperatorcondensate drain nipple.3. Use a funnel to feed water into the top of the condensatetube.4. Continue filling until water begins to flow out throughthe condensate line (Figure 70, item 4).5. Re-attach the condensate trap to the bottom of therecuperator. Secure with the hose clamp.6. Check for any leaks in the condensate drain line or fittings.Repair any leaks.7. Remove the temporary clamp (see step 2, above) fromthe condensate drain tube.The condensate trap must be filled with waterduring all times of boiler operation to avoidflue gas emission from the condensate drainline. Prime the condensate trap by pouringwater into the outlet tee while restricting flowin drain tube if boiler has been out of servicefor an extended period. Failure to fill the trapcould result in severe personal injury or death.Figure 70 Condensate trap assemblyCheck thermostat circuit(s)1. Disconnect the two external wires connected to the boiler thermostatterminals (see Field wiring, beginning on page 56 for terminallocations).2. Connect a voltmeter across these two incoming wires. Close eachthermostat, zone valve and relay in the external circuit one at atime and check the voltmeter reading across the incoming wires.3. There should NEVER be a voltage reading.4. If a voltage does occur under any condition, check and correct theexternal wiring. (This is a common problem when using 3-wirezone valves.)Part number 550-142-054/1211 61
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Boiler Manual - Weil-McLain

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