Weil-McLain GV90+ Manual

Series 2 gas-fired water boilers beginning serial number: cp7538624

Hide thumbs Also See for GV90+:

Installation and start-up manual (108 pages)

Manual (108 pages)

User's information manual (17 pages)

100

101

102

103

104

105

106

107

108

Table Of Contents

109

Table of Contents

Quick Links

Troubleshooting

Need help?

Do you have a question about the GV90+ and is the answer not in the manual?

Questions and answers

Summary of Contents for Weil-McLain GV90+

Page 1 ® Beginning Serial Number: CP7538624 Series 2 Gas-Fired Water Boilers Boiler Manual • Installation • Maintenance • Startup • Parts This manual must only be used by a qualified heating installer/service technician. BEFORE installing, read all instructions in this manual and all other information shipped with the boiler. Perform steps in the order given.
Page 2: How It Works
— Boiler Manual GV90+ Series 2 FIRED WATER BOILER How it works . . . The integrated boiler control (IBC) responds to signals from the room thermostat, air LEGEND pressure switch, inlet water sensor, boiler water temperature sensor and boiler limit circuit to operate the circulators, gas valve, igniter and blower.
Page 3 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER GV90+ Series 2 Part number 550-142-903/1016...
Page 4 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Contents Hazard deﬁnitions The following deﬁned terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product. Indicates presence of hazards that will cause Indicates presence of hazards that will or can severe personal injury, death or substantial...
Page 5: Please Read Before Proceeding
See the instructions contact with water, replace the boiler with a new Weil-McLain boiler. at right. Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage.
Page 6: Prepare Boiler Location
— Boiler Manual GV90+ Series 2 FIRED WATER BOILER Prepare boiler location Installations must follow these codes: Estimated GV90+ input at altitude cal, state, provincial, national codes, laws, regulations and ordinances. Altitude % Sea level input (feet) Boilers, ANSI/ASME CSD-1, when required. 1,000 2,000 Natural Gas and Propane Installation Code, B149.1...
Page 7: Residential Garage Installation
Wall GV90+5 / GV90+6 37¾ Area adjacent to access door must be accessible and must allow for removal of the GV90+boiler * Increase height if needed to ensure for service. condensate trap outlet tee is above inlet No other appliance or air mover (exhaust fan, of condensate pump, when used.
Page 8: Prepare The Boiler
Access the bottom of the blower housing as shown in Figure 5. To inspect the plate only, . It must read the same as the boiler size and fuel, as follows: GV90+3 NG 3 SEC LP 3 SEC GV90+4 NG 4 SEC...
Page 9 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Prepare the boiler (continued) Install condensate trap Install condensate trap 1. Before placing the boiler in position, install the condensate trap line, shown in Figure 7. Items shown are provided with the boiler. Attach the ﬂue drain hose (C) to the in-line ﬂue drain nipple (B).
Page 10 Carefully follow the guidelines given in this manual. 2. Obtain the GV90+ high altitude kit from your local Weil-McLain distributor. The high altitude kit contains the high altitude air Interior panel top pressure switch.
Page 11 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Prepare the boiler (continued) Perform hydrostatic pressure test Piping connections for hydrostatic test Pressure test boiler attaching water or gas piping (except as noted below) or electrical supply. Remove jacket top panel before proceeding.
Page 12 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Install water piping , using one of the wrenches to prevent the boiler Install an in the piping as shown in this interior piping from turning. Failure to support the boiler manual.
Page 13: Expansion Tank
— Boiler Manual GV90+ Series 2 FIRED WATER BOILER Install water piping (continued) Expansion tank Relief valve installation guidelines Figure 14, page 14 and Figure 15, page 14 show typical installation of the expansion tank. Always locate the air separator and expansion tank as shown in the suggested piping drawings, beginning with Fig- ure 17, page 16.
Page 14 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Install water piping (continued) Piping to single-zone system using diaphragm- or Piping closed-type expansion tank bladder-type expansion tank. Boiler connections are 1” NPT (supply from 1” tee, return to 1” recuperator ﬂange).
Page 15: System Water Piping Methods
— Boiler Manual GV90+ Series 2 FIRED WATER BOILER Install water piping (continued) System water piping methods Simpliﬁed pipe/circulator selection 1. Install the boiler and piping using the recommended piping Most piping methods shown in this manual use layouts in this manual. primary/secondary connection to the boiler loop.
Page 16 Figure 18, page 17 for application on systems using baseboard (ﬁnned tube or cast iron). Boiler loop pipe size — Substitute a memory-stop GV90+3/4 1” valve for one of the isolation valves in each zone to use the GV90+5/6 1¼”...
Page 17 * This application may be marginal. It could cause temperature distribution problems, because the temperature drop is 30°F, NOT 20°F. The best method is to use primary/secondary piping for the GV90+5 as in Figure 20, page 18. Part number 550-142-903/1016...
Page 18 Provide a separate 24-volt — Boiler loop pipe size transformer to power the zone valves. Size the trans- GV90+3/4 1” former to handle the total rated load of all connected GV90+5/6 1¼” zone valves. Alternatively, use a zone valve zone controller.
Page 19 Boiler loop pipe size For additional information and alternatives in piping for radiant heat- GV90+3/4 1” ing systems, contact Weil-McLain. GV90+5/6 1¼” Adjust balancing valves Use valves 17 and 18 to mix boiler supply water with system return water, reducing supply water temperature to the system.
Page 20 Size the trans- former to handle the total rated load of all connected Boiler loop pipe size zone valves. Alternatively, use a zone valve zone controller. GV90+3/4 1” GV90+5/6 1¼” — The GV90+ internal system circulator cannot be removed from the boiler for use as one of the zone circulators.
Page 21 Substitute a memory-stop valve for one of these in each zone in order to use the memory-stop valve Boiler loop pipe size for balancing ﬂow as well as isolation. GV90+3/4 1” GV90+5/6 1¼” Provide a separate 24-volt transformer to power the zone valves.
Page 22 If boiler is connected to heating coils located in air handling units where they can be exposed to refrigerated air, use ﬂow control valves or other automatic means to prevent gravity circulation during cooling cycle. Boiler loop pipe size GV90+3/4 1” — Substitute a memory-stop GV90+5/6 1¼”...
Page 23: Multiple Boiler Installations
T-T terminals). Piping multiple GV90+ boilers 1. See suggested piping diagrams in this manual. Contact Weil-McLain for assistance for systems not covered. 2. Always pipe the boilers on a secondary loop in a primary/secondary circuit as shown in the examples in this manual.
Page 24: Multiple Boiler Water Piping
— Boiler Manual GV90+ Series 2 FIRED WATER BOILER Multiple boiler water piping Easy-Fit® piping installation ® 1. Main header and Easy-Fit Manifold pipe sizing. a. New system — See page 15. b. Replacing boilers in an existing system — Without reducing size, connect system supply and return lines.
Page 25 Series 2 FIRED WATER BOILER Multiple boiler water piping (continued) Piping schematic — typical for multiple GV90+ boilers, using Weil-McLain Easy-Fit manifolds 1 Flow/check valve (each boiler) 11 Check valve or backﬂow preventer, as required by applicable codes 2 Isolation valves (when used)
Page 26 FIRED WATER BOILER Multiple boiler water piping (continued) Piping layout — typical for multiple GV90+ boilers, using Weil-McLain Easy-Fit manifolds (2-boiler system) 1 Flow/check valve (each boiler) 17 3-way diverting valve (operated by DHW aquastat — valve end 2 Isolation valves (when used)
Page 27 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Multiple boiler water piping (continued) Piping layout — typical for multiple GV90+ boilers, with DHW storage heaters (4-boiler system) Flow rate Size Flow rate Size Suggested DHW 1 – 4 gpm ¾”...
Page 28 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Multiple boiler water piping (continued) Piping layout — typical for multiple GV90+ boilers, using isolation exchanger 1. Large volume systems with high mineral content in water. 2. Systems exposed to untreated quantities of makeup water.
Page 29 Seal any unused open- installation, contact Weil-McLain for ings in the common venting system. assistance. Other conﬁgurations may be available.
Page 30 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Venting & air — general (continued) Provide combustion air: Combustion air contamination: DIRECT VENT place combustion air supply DIRECT EXHAUST openings or intake terminations near a swimming pool, for example. Avoid areas subject to exhaust fumes ALL APPLICATIONS from laundry facilities.
Page 31 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Venting & air — general (continued) Manifolded combustion air Combustion air manifold option (combined air inlet, but option for DIRECT VENT individual vents) — must comply with Figure 41, page 35 multiple boiler installations 1.
Page 32 DIRECT EXHAUST (combustion air piped to boiler from outside) (combustion air from inside) SIDEWALL VERTICAL SIDEWALL VERTICAL termination termination termination termination Weil-McLain 3” PVC 3” PVC 3” PVC 3” PVC 3” PVC 3” PVC vent/air cap Separate pipes Concentric Separate pipes...
Page 33 AL29-4C vent piping — Install a PVC-to-stainless adapter supplied by the vent pipe manufacturer at the boiler vent connection and at the termination (when using Weil-McLain plate or concentric PVC termination). DO NOT mix piping from different vent pipe manufacturers unless using adapters speciﬁcally designed for the purpose by the manufacturer.
Page 34: Commonwealth Of Massachusetts Installations
— Boiler Manual GV90+ Series 2 FIRED WATER BOILER Commonwealth of Massachusetts installations Commonwealth of Massachusetts — (a) For all sidewall horizontally-vented gas-fueled equipment . The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall installed in every dwelling, building or structure used in not approve the installation unless, upon inspection, whole or in part for residential purposes, including those...
Page 35: Vent Termination Requirements
— Boiler Manual GV90+ Series 2 FIRED WATER BOILER Vent termination requirements The vent termination must be located to meet all requirements below (also applies to vertical vent terminations). The minimum distance from adjacent public walkways, adjacent buildings, openable windows and building in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1.
Page 36 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER DIRECT VENT — Boiler room air openings Combustion and ventilation air openings for GV90+ Direct Vent installations The GV90+ boiler CANNOT be in the same space with other appliances if clearances around the GV90+ are less than the recommended service clearances shown in Figure 2, page 6.
Page 37 Prepare the sidewall penetrations and secure the sidewall vent connection. It is not classiﬁed as a forced air plates as instructed in this section. See “Install Weil-McLain intake with regard to spacing from adjacent boiler vent/air cap” on page 38.
Page 38 ﬂue pipe and air pipe. Level the template with a spirit level. For the Weil-McLain plate, the template must be level to ensure the ﬂue and air pipe will be side-to-side, as shown in Figure 45. Failure to comply could result in severe personal injury, death or substantial property damage.
Page 39 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER DIRECT VENT — — Separate pipes sidewall Use only the vent materials and kits listed in Figure 40, page 33. Provide pipe adapters if speciﬁed. 1. Locate the termination such that the total air piping and vent piping from the boiler to the termination will not exceed the maximum length given in Figure 39, page 32.
Page 40 3. Use a sidewall termination plate as a template for correct location of hole centers. Sidewall termination plates are included with the Weil-McLain sidewall vent/air plate kit, shipped with each boiler. 4. Follow all local codes for isolation of vent pipe when passing through ﬂoors or walls.
Page 41 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER DIRECT VENT — — Concentric horizontal 1. The 3” concentric termination kit must be pur- chased separately. Use only the vent materials and kits listed in Figure 40, page 33. Provide pipe adapt- ers if speciﬁed.
Page 42 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER DIRECT VENT — (continued) Termination location — concentric 1. Assemble the vent termination as described for concentric termi- termination — multiple boilers — clearance nations, on page 47. from vent of one to air intake of the next If necessary, you can shorten the lengths of the inner and outer pipes for a shorter ﬁnished assembly.
Page 43 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER DIRECT VENT — Separate pipes vertical termination Use only the vent materials and kits listed in Figure 40, page 33. Provide pipe adapters if speciﬁed. 1. Locate the terminations such that the total air piping and vent piping from the boiler to the termination will not exceed the maximum length given in Figure 39, page 32.
Page 44 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER DIRECT VENT — (continued) 3. Space the air and vent holes to provide the minimum spacings Terminations for multiple boilers shown in Figure 53, page 43. 4. Follow all local codes for isolation of vent pipe when passing through ﬂoors, ceilings and roofs.
Page 45 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER DIRECT VENT — — Concentric vertical 1. The 3” concentric termination kit must be pur- chased separately. Use only the vent materials and kits listed in Figure 40, page 33. Provide pipe adapters if speciﬁed.
Page 46 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER DIRECT VENT — (continued) 3. Provide ﬂashing and sealing boots sized for the concentric termi- Vertical termination — 3” PVC concentric nation outside diameter. — single or multiple boilers 1. Mount the termination as shown in Figure 57, page 46. 2.
Page 47 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Concentric termination assembly 3” PVC concentric termination assembly — DO NOT attach the rain cap until the termination has been 1. See Figure 58, page 47 for the details of the termi- inserted through the roof or wall and all supports have nation assembly.
Page 48: Vent And Air Piping And Boiler Connections
AL29-4C stainless vent starter at the proper ﬁt before assembling any joint. boiler vent connection (and at the termination if using the Weil-McLain plate or the concentric termination). 8. For each joint: Use only the starter made by the vent pipe manufacturer.
Page 49 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER DIRECT EXHAUST — Boiler room air openings Combustion air provision Special considerations The GV90+ boiler can use inside air if no contaminants are pres- Tight construction ent in the boiler space. (If contaminants are likely to be present, install the boiler as a direct vent appliance, using the appropriate ANSI deﬁnes unusually tight construction...
Page 50 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER DIRECT EXHAUST — Boiler room air openings (cont.) MINIMUM combustion air openings for direct exhaust applications — The GV90+ boiler CANNOT be in the same space with other appliances if If the space is smaller than clearances around the GV90+ are less than the recommended service clearances Figure 2, page 6, provide shown in Figure 2, page 6.
Page 51 ﬁttings” on page 52. a. External venting greater than 4 feet The vent piping can terminate using the Weil-McLain vent/air plate (without requires an enclosure around the vent air piping connected). It can also terminate using a coupling or down-turned pipe.
Page 52 (or elbow when snorkeled). 7 Snorkel option (to elevate vent termination) — requires bird screen 8 Coupling option — requires bird screen 9 Weil-McLain termination plate option (plate is supplied with boiler) — bird screen not required Part number 550-142-903/1016...
Page 53 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER DIRECT EXHAUST — Vertical — Direct exhaust vertical Use only the vent materials and kits listed in Figure 40, page 33. Provide pipe adapt- ers if speciﬁed. 1. Locate the termination such that the total air piping and vent piping from the boiler to the termina- tion will not exceed the maximum length given in Figure 39, page 32.
Page 54: Gas Piping
— Boiler Manual GV90+ Series 2 FIRED WATER BOILER Gas piping Connecting gas supply piping Gas supply connection to GV90+ boiler gas manifold Do not connect gas supply to boiler or at- tempt to operate boiler unless the correct oriﬁce plate has been veriﬁed or installed in accordance with page 8.
Page 55 To replace wiring, order complete harness assem- Install 100% lockup gas pressure regulator in sup- blies from Weil-McLain. If any original wiring as ply line if inlet pressure exceeds 14” water column. supplied with boiler must be replaced, and a har- Adjust for 14”...
Page 56: Wiring Multiple Zones
— Boiler Manual GV90+ Series 2 FIRED WATER BOILER Wiring (continued) Field wiring connections — service switch and thermostat (or end switch) provided by installer Thermostat wires are labeled “T-T” on boiler. Remove label boiler, disconnect ﬁeld thermostat wires at boiler. Place a volt- before connecting as shown in Figure 66.
Page 57 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Wiring (continued) Ladder wiring diagram Part number 550-142-903/1016...
Page 58 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Wiring (continued) Schematic wiring diagram Part number 550-142-903/1016...
Page 59: Water Chemistry
Usually indicates return water temperature sensor Antifreeze detects water at boiler return pipe less than 40°F. 1. Use only antifreeze listed by Weil-McLain as suitable for use Both internal circulators will run continuously, with GV90+ boilers. A list of approved antifreeze products even with no call for heat, until temperature rises.
Page 60 2. See Replacement parts, Figure 96, page 91 of this manual for b. Pressure will rise when boiler is turned on and sys- tem water temperature increases. Operating pressure Weil-McLain part numbers to obtain antifreeze through a Weil- must never exceed 5 PSIG less than the boiler relief McLain distributor.
Page 61: Check For Gas Leaks
— Boiler Manual GV90+ Series 2 FIRED WATER BOILER Start-up (continued) 5. Once the external thermostat circuit wiring is checked and corrected if necessary, reconnect the external ther- Check for gas leaks mostat circuit wires. Allow the boiler to cycle. Before starting the boiler, and during initial opera- Inspect/ﬁll condensate system tion, use a leak detector or smell near the ﬂoor and...
Page 62 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Start-up (continued) Final checks before starting boiler IMPORTANT ❏ Review the boiler sequence of operation in Figure 75, page 66. ❏ In accordance with Section 325 (f) (3) of the Energy Policy Verify that the boiler and system are full of water and all system and Conservation Act, this boiler is equipped with a feature components are correctly set for operation.
Page 63 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Start-up (continued) 5. Position and zero manometer per manufacturer’s instructions. Check for igniter glow by looking into The manometer must have at least 6” of tubing above the ﬂuid observation port on front of blower housing level or ﬂuid may be drawn into the gas valve.
Page 64: Final Checklist
— Boiler Manual GV90+ Series 2 FIRED WATER BOILER Start-up (continued) Final checklist 1 Gas control outlet pressure tap — located on back side of gas control. Use tap closest to gas control gas outlet —Remove screw from gas control outlet pressure tap and slide hose over tap 2 Add tee hose ﬁtting as shown 3 Existing hose to gas control vent tap hose barb —...
Page 65 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Start-up (continued) d. IBC will begin purge cycle, then activate igniter. ❏ Cycle boiler with thermostat — Raise to highest setting and Igniter will glow for approximately 35 seconds. verify boiler goes through normal start-up cycle. Lower to Near end of 35 seconds, 24 VDC will show at gas lowest setting and verify boiler goes off.
Page 66 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Start-up (continued) Integrated boiler control (IBC) sequence of operation — status light indications STEPS TSTAT PRESS SENSOR POWER LIMIT FLAME CIRC SWITCH (After Step 9, the cycle goes back to Step 1) —...
Page 67 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Start-up (continued) Operating instructions Part number 550-142-903/1016...
Page 68 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Annual start-up and general maintenance schedule Service and maintenance schedules (see following pages for instructions) (see following pages for instructions) General: Daily Monthly Periodically Every 6 months Additional if combustion or performance indicates the need: End of season...
Page 69: Address Reported Problems
— Boiler Manual GV90+ Series 2 FIRED WATER BOILER Annual start-up Inspect all piping for leaks Annual start-up only by qualiﬁed Eliminate all system or boiler leaks. Continual service technician fresh make-up water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating heat exchanger, and The boiler should be inspected and started annu- causing heat exchanger failure.
Page 70 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Annual start-up (continued) Inspect expansion tank Igniter observation port in blower 1. Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools.
Page 71 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Annual start-up (continued) Inspect temperature mixing system Blower motor 1. Carefully check the of the as it passes through the boiler jacket and on the just before it enters the boiler sections.
Page 72: Review With Owner
— Boiler Manual GV90+ Series 2 FIRED WATER BOILER Annual start-up (continued) Relief valve Inspect boiler relief valve 1. Inspect the relief valve (Figure 80) and lift the lever to verify ﬂow as in the following warnings, excerpted from a relief valve manufacturer’s warning label.
Page 73 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Service & maintenance Cleaning boiler heating surfaces Blower housing removal procedure The service procedures in this manual must only be performed by a qualiﬁed boiler service technician. Failure to com- ply could result in severe personal injury, death or substantial property damage.
Page 74 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Service & maintenance (continued) Recuperator access and cleaning The burner may contain ceramic ﬁber par- ticles. Use care when handling these materials per instructions on page 106 of this manual. Failure to comply could result in severe per- sonal injury.
Page 75 9. Rinse the recuperator thoroughly. If the recuperator shows signs of signiﬁcant cor- rosion or deterioration, contact Weil-McLain for recommendations on investigating the cause and replacing the recuperator if necessary. 1. Inspect the recuperator gaskets to make sure all are in good condition.
Page 76 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Troubleshooting VERIFY PROPER OPERATION AFTER Connecting a manometer to check SERVICING. air pressure switch. DO NOT use this arrangement to check gas valve Label all wires prior to disconnection when servicing controls.
Page 77: Gas Valve
— Boiler Manual GV90+ Series 2 FIRED WATER BOILER Troubleshooting (continued) Igniter Igniter Wait several minutes until igniter cools down before at- tempting replacement. Failure to do so will cause severe personal injury. 1. Disconnect igniter (Figure 85) from igniter wiring harness and remove igniter before removing from blower assembly.
Page 78 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Troubleshooting (continued) Return temperature sensor Supply Temperature sensor 1. See Figure 89. See Figure 91. 2. Resistance check method: 2. The boiler temperature sensor is a resistance-type device. a. With the boiler operating, use a contact thermometer to measure the temperature of the return pipe next to the re- 3.
Page 79 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Troubleshooting (continued) Control indicator lights — GV90+ Integrated Boiler Control (IBC) HARD LOCKOUT Summary (Flashing LED’s) MAY remove 120VAC power for more than 2 seconds to clear lockout OR ignition control will automatically restart sequence of operation after 1 hour waiting period after fault condition is cleared.
Page 80 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Troubleshooting (continued) IBC harness plug receptacle and indicator light locations Part number 550-142-903/1016...
Page 81 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Troubleshooting (continued) Common causes and possible corrections, part 1 Symptom Common Causes Possible Corrections Rapid cycling — boiler Thermostat installed where drafts Locate thermostat on inner wall away from turns on and off frequently or heat affect reading heat sources or cool drafts.
Page 82 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Troubleshooting (continued) Common causes and possible corrections, part 2 Symptom Common Causes Possible Corrections Popping or percolating Mineral deposits in sections due Call qualiﬁed service technician to de- noise heard in boiler to constant use of makeup water lime boiler, if necessary.
Page 83 Using voltmeter, check across pins of receptacle. light ﬂashing now? Does voltmeter indicate Have system checked by a Replace IBC. Boiler should now operate Replace transformer. licensed electrician. normally. Retest. Retest. If problem persists, call your local Weil-McLain sales repre- sentative. Part number 550-142-903/1016...
Page 84 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Troubleshooting (continued) CHART 2 TSTAT/CIRC & POWER lights ﬂashing — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. Is return water temperature sensor clamped Attach sensor to pipe with clamp provided.
Page 85 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Troubleshooting (continued) CHART 3 PRESS SWITCH & POWER lights ﬂashing — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. Reset boiler control by turning off power at service switch or Thermostat should call for heat and appropriate zone valves turning down thermostat for at least 45 seconds.
Page 86 Wait 5 minutes. & lights ﬂashing? Boiler should now operate normally. Original ﬂashing light caused by gas valve not operating properly. Call your local Weil-McLain See normal sequence of operation (Figure 75, page 66). sales representative. Part number 550-142-903/1016...
Page 87 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Troubleshooting (continued) CHART 5 TSTAT/CIRC light ﬂashing and POWER light on steady — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. This is NOT a lockout mode.
Page 88 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Troubleshooting (continued) CHART 6 LIMIT light ﬂashing and POWER light on steady — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. This is NOT a lockout mode.
Page 89 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Troubleshooting (continued) CHART 7 Insufﬁcient heat or no heat to system (POWER light on steady) — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. Has it been at least 5 minutes since setting thermostat to Is boiler System circulator operating? call for heat? If not, wait 5 minutes.
Page 90 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Troubleshooting (continued) Troubleshooting Sensor Ground and POWER light Solid CHART 8 and/or “LCO” shown on display — Wherever you see TURN OFF POWER, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. Is harness securely connected to control? Secure connector.
Page 91 Adapter 3-inch AL29-4C Vent Starter, Saf-T-Vent 560-907-724 Adapter 3-inch AL29-4C Vent Starter, CORR/GUARD Contact Weil-McLain Chemicals: Antifreeze, aluminum-safe, Sentinel X500 ..... . .
Page 92 FIRED WATER BOILER Replacement parts (continued) Section assembly Item Description Model Weil-McLain number part number Block assembly, includes: 322-200-304 Front section, intermediate section, back section, square cut seals — 2”, 322-200-305 VLOLFRQH VHDODQW WLH URGV WLH URG QXWV WLH URG ZDVKHUV EORZHU ÀDQJH...
Page 93 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Replacement parts (continued) Section assembly Part number 550-142-903/1016...
Page 94 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Replacement parts (continued) Jacket assembly Item Description Model Weil-McLain number part number 3 & 4 382-200-739 Jacket panel, top 5 & 6 382-200-740 Jacket panel, front 382-200-702 382-200-730 382-200-731 Jacket panel, left side, front...
Page 95 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Replacement parts (continued) Jacket assembly Part number 550-142-903/1016...
Page 96 GV90+ Series 2 FIRED WATER BOILER Replacement parts (continued) Blower assembly Item Description Model Weil-McLain number part number %XUQHU UHSODFHPHQW NLW LQFOXGHV EXUQHU EORZHU ÀDQJH JDVNHW LJQLWHU LJQLWHU 382-200-320 screws, igniter washers, igniter gasket 382-200-325 382-200-330 382-200-335 %ORZHU ÀDQJH JDVNHW...
Page 97 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Replacement parts (continued) Blower assembly Part number 550-142-903/1016...
Page 98 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Replacement parts (continued) Trim assembly Item Description Weil-McLain number part number System circulator, Taco 007 511-405-113 Bypass circulator, Taco 007 511-405-113 Circulator gasket, Taco 110-339 590-317-543 Manifold, casting/circulator kit, includes water manifold, circulator gasket (Taco...
Page 99 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Replacement parts (continued) Trim assembly Part number 550-142-903/1016...
Page 100 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Replacement parts (continued) Interior panel Item Description Weil-McLain number part number Interior panel see Figure 99, page 94, item 8 Integrated boiler control assembly, includes IBC and screws 381-330-023 Transformer 381-356-578...
Page 101 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Replacement parts (continued) Interior panel Part number 550-142-903/1016...
Page 102: Dimensions And Ratings
— Boiler Manual GV90+ Series 2 FIRED WATER BOILER Dimensions and ratings Dimension drawing (see Figure 108, page 103 for dimensional table) 1” NPT Supply 1” NPT Return Combination pressure-temperature gauge, 2 ½” short shank ¾” NPT Relief valve outlet Plug dome, 2”...
Page 103 (includes the internal circulators) inches NPT inches NPT inches) inches NPT (amperes) (gallons) male) female) female) GV90+3 30¾ ½ GV90+4 30¾ ½ GV90+5 37¾ ½ GV90+6 37¾ ½ Note 1: Gas piping from meter to boiler to be sized per local utility requirements.
Page 104 Based on standard test procedures outlined by DOE for individual boilers. Net AHRI ratings are based on piping and pickup allowance of 1.15. Note 2 Consult Weil-McLain Technical Services for other allowances. All GV90+ installations require a separate vent pipe and termination for each boiler. . Install and terminate vents as described in vent/air installation instructions in this manual.
Page 105 GV90+ Series 2 FIRED WATER BOILER Dimensions and ratings (continued) Engineering data — see page 103 for additional technical information GPM @ 20°F rise GPM @ 40°F rise Note 1 GV90+3 3” GV90+4 3” GV90+5 13.0 3” GV90+6 16.1 3”...
Page 106 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER Handling ceramic ﬁber and ﬁberglass materials This boiler contains ceramic ﬁber materials that This product contains ﬁberglass jacket insula- have been identiﬁed as carcinogenic, or possibly tion and ceramic ﬁber materials in combus- carcinogenic, to humans.
Page 107 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER NOTES Part number 550-142-903/1016...
Page 108 — Boiler Manual GV90+ Series 2 FIRED WATER BOILER...

Weil-McLain GV90+ Manual

Quick Links

Troubleshooting

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Weil-McLain GV90+

Summary of Contents for Weil-McLain GV90+

Table of Contents