Boiler Manual - Weil-McLain

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GV90+ gas-fired water boiler — Boiler ManualService & maintenanceCleaning boiler heating surfacesThe service procedures in this manualmust only be performed by a qualifiedboiler service technician. Failure to complycould result in severe personal injury,death or substantial property damage.Figure 81 Blower housing removal procedureThe boiler contains ceramic fiber andfiberglass materials. Use care when handlingthese materials per instructionson page 107 of this manual. Failure tocomply could result in severe personalinjury.1. If inspection of the boiler flueways indicates the presenceof soot, clean the boiler heating surfaces using thefollowing procedure. The process requires removingthe blower housing to allow spraying waterthrough the boiler combustion chamber.2. Before proceeding, obtain a GV90+ gasket replacementkit, consisting of igniter, recuperator, fluewayinspection port and blower flange gaskets.To remove the blower assembly1. Turn off boiler by turning down the thermostat.Then turn off power at the boiler service switch.Close manual gas valve on incoming gas line toboiler.Turn off power and gas to the boiler.Failure to do so can cause severe personalinjury, death or substantial propertydamage.Wait several minutes after boiler hasstopped to allow the igniter to cool toavoid severe personal injury or death.2. See Figure 81.3. Disconnect:a. Remove union outside of boilerb. Gas tubing from gas valve outlet by removingthe 4 screws securing the outlet fitting to thevalve. (Save the o-ring in the fitting.)c. Remove gas valve and bracketd. Hose from gas valve to gas/air manifolde. Pressure switch hosesf. Air inlet hoseg. Blower motor wiring harness from IBCh. Igniter harness connected to igniter plugi. Blower support bracket (remove screw securingblower housing to bracket — on left side ofblower housing)j. Ground wire.4. Remove the two igniter screws and washers. Carefullyremove the igniter. Use care when handling —igniter is very brittle. DO NOT touch igniter surfacewith hands or expose to any greasy substances.5. Remove nuts from studs securing blower housingto front section.1 Blower assembly2 Blower support bracket3 Blower motor wiring harness4 Air pressure switch5 Blower flange gasket (replace this)6 Burner cone and ring assembly7 Igniter gasket (replace this)8 Gas/air orifice plate9 Red pressure switch hose10 White pressure switch hose11 Inlet air hose and clamps12 Gas tubing13 Igniter14 Gas valve and bracket6. Grasp blower housing and pull free from studs. Turn clockwise slightly,until blower assembly can be removed safely from inside of boiler jacket.7. Remove burner cone and gasket for inspection.To clean heating surfaces1. Remove the flueway inspection port cover (page 3, item g), if not alreadyoff of the boiler.2. Place a catch pan under the inspection port to catch the cleaningwater.3. Spray water into the boiler combustion chamber opening.4. Catch the runoff water in the pan below the inspection port.5. Continue process until flueways are clean.72Part number 550-142-054/1211
GV90+ gas-fired water boiler — Boiler ManualService & maintenance (continued)To clean the burnerThe burner may contain ceramic fiber particles. Usecare when handling these materials per instructions onpage 107 of this manual. Failure to comply could resultin severe personal injury.1. Clean the burner ports with a soft brush.2. Use compressed air to blow out any particulate if necessary. Usecaution to avoid particulate being blown into the building.To replace blower assembly1. Place a new blower flange gasket over the studs at combustionchamber opening.2. Reinstall burner cone into chamber opening.3. Position blower assembly over studs. Install nuts and tighten.4. Install igniter and new igniter gasket. Fasten with screws and washers.Tighten only with hand-held screwdriver. DO NOT use electricor pneumatic driver. Excessive torque will damage igniter. Do notexceed 20 inch-pounds torque.5. Connect:a. Gas valve and piping (4 screws)b. Gas tubing to gas valve outletc. Pressure switch hosesd. Hose from gas valve to gas/air manifolde. Air inlet hosef. Blower motor wiring harness to IBCg. Igniter harness to igniter plugh. Blower support bracket (with screw)i. Ground wire.6. Be sure all wiring and hose connections are correct per Figure81, page 72and are secure on the hose barb fittings.Figure 82 Recuperator access and cleaningFigure 83 Recuperator with access panel removed(GV90+3/4 top, GV90+5/6 bottom)Inspecting and cleaning the recuperatorTurn off power and gas to the boiler. Failure to do socan cause severe personal injury, death or substantialproperty damage.Wait several minutes after boiler has stopped to allowthe boiler components to cool to avoid severe personalinjury or death.1. Remove the recuperator access panel and gasket (see Figure 82)and inspect the interior with a flashlight.2. If there are indications of debris or corrosion, disconnect thecondensate trap from the bottom of the recuperator and place acatch pan underneath.3. Flush the flueway (Figure 83, item 1) and tubes (Figure 83, item 2)thoroughly with fresh water, allowing the water to drain outthrough the recuperator condensate opening.4. If all of the water doesn't drain from the flueway (Figure 83,item 1), the drain holes (see Figure 84) may be plugged. Removethe recuperator using the procedure under Removing/cleaning/re-installing the recuperator, page 74.Part number 550-142-054/1211 73
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Boiler Manual - Weil-McLain

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