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Weil-McLain 2 Series Manual

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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. Failure to comply could result in severe personal injury, death or substantial property damage.
Series 2
Gas-Fired Water Boilers
Now With Built In
Low Water Cut Off Functionality
Part number 550-143-010/1021

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  • Page 1 Series 2 Gas-Fired Water Boilers Boiler Manual • Installation • Maintenance Now With Built In Low Water Cut Off Functionality • 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

    series gas-fired water boiler – boiler manual GV90+ How it works . . . 1 Integrated boiler control The Integrated Boiler Control (IBC) responds to signals from the room thermostat, air LEGEND pressure switch, inlet water sensor, boiler water temperature/LWCO sensor and boiler limit circuit to operate the circulators, gas valve, igniter and blower.

  • Page 3: Gv90+ Series 2 Water Boiler

    series gas-fired water boiler – boiler manual GV90+ GV90+ Series 2 Water Boiler Part number 550-143-010/1021...

  • Page 4: Table Of Contents

    series gas-fired water boiler – boiler manual GV90+ Contents How it works ..... . .2 DO NOT START THIS BOILER without following all instructions and procedures GV90+ Series 2 Water Boiler .

  • Page 5: Please Read Before Proceeding

    See the instructions 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

    series gas-fired water boiler – boiler manual GV90+ Prepare boiler location Installations must follow these codes: Estimated GV90+ input at altitude Figure 1 • Local, state, provincial, national codes, laws, regulations and ordinances. Altitude • National Fuel Gas Code, ANSI Z223.1/NFPA 54 - latest edition. % Sea level input (feet) •...
  • Page 7 series gas-fired water boiler – boiler manual GV90+ Prepare boiler location (continued) Foundation Minimum clearances — when Figure 4 clearances are less than recom- Provide a solid brick or concrete foundation pad if any of the following mended service clearances of Fig- is possible: ure 2, page...
  • Page 8 series gas-fired water boiler – boiler manual GV90+ Prepare the boiler (continued) Check orifice plate — replace if Check for correct gas orifice plate Figure 5 necessary must be used. Failure to do correct orifice plate A Remove jacket front so will result in severe personal injury, death or sub- panel to access the bot- stantial property damage.
  • Page 9 series gas-fired water boiler – boiler manual GV90+ Prepare the boiler (continued) Install condensate trap Install condensate trap Figure 7 Before placing the boiler in position, install the condensate trap, shown in Figure 7. Items shown are provided with the boiler. 1.
  • 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 pressure switch.
  • Page 11 series gas-fired water boiler – boiler manual GV90+ Prepare the boiler (continued) Perform hydrostatic pressure test Piping connections for hydrostatic test Figure 10 Pressure test boiler attaching water or gas piping (except as before noted below) or electrical supply. Remove jacket top panel before proceeding.

  • Page 12: Install Water Piping

    series gas-fired water boiler – boiler manual GV90+ Install water piping Air separator Use two wrenches when tightening water piping at , using one of the wrenches to prevent the boiler boiler Install an air separator in the piping as shown in this interior piping from turning.
  • Page 13 series gas-fired water boiler – boiler manual GV90+ Install water piping (continued) Expansion tank Relief valve installation guidelines Figure 13 Figure 14, page 14 Figure 15, page 14 show typical installation of the expansion tank. Always locate the air separator and expansion To avoid water damage or scalding tank as shown in the suggested piping drawings, beginning with Fig- due to relief valve operation, as per...
  • Page 14 series gas-fired water boiler – boiler manual GV90+ Install water piping (continued) Piping to single-zone system using diaphragm- or Piping closed-type expansion tank Figure 14 Figure 15 bladder-type expansion tank. Boiler connections are 1” NPT (supply from 1” tee, return to 1” recuperator flange).
  • Page 15 For other piping methods, consult your local a. Determine the heating load (Btuh) for each circuit. Weil-McLain representative. b. Calculate the flow rate for each circuit using its load. To use a 20°F temperature drop, just divide the Circulators MBH (1,000’s of Btuh) by 10.
  • Page 16 series gas-fired water boiler – boiler manual GV90+ Install water piping (continued) Baseboard system piping — Baseboard system — circulator zoning Figure 17 CIRCULATOR zoning (primary/secondary) Apply Figure 17 for circulator zoning on systems using baseboard heaters. The heaters can be any baseboard style, including finned tube or cast iron. —...
  • Page 17 series gas-fired water boiler – boiler manual GV90+ Install water piping (continued) Zone valve zoning — GV90+3, GV90+4 or GV90+5 Figure 18 (DO NOT apply to GV90+6) Legend 1 Isolation valves 4 Zone valve 2 Automatic air vent (with 7 Hose bibb purge valve diaphragm-type expan- 8 Boiler pressure/tempera- sion tank), or connect to...
  • Page 18 series gas-fired water boiler – boiler manual GV90+ Install water piping (continued) Radiator system piping Radiator system — zone-valve zoning Figure 20 Apply Figure 20 (zone-valve zoning) or Figure 21 (circulator zoning) to systems using standing cast iron radiators. This applies to gravity water systems and converted steam systems using columnar, tubular or recessed cast iron radiators.
  • Page 19 MINIMUM For additional information and alternatives in piping for radiant heat- Boiler loop pipe size ing systems, contact Weil-McLain. GV90+3/4 1” The system circulator must be supplied by the in- GV90+5/6 1¼”...
  • Page 20 series gas-fired water boiler – boiler manual GV90+ Install water piping (continued) Multi-zone radiant heating system Auto system supply temp regulation — Figure 23 zone valve zoning Multi-zone systems require automatic regulation of the system sup- ply temperature because of widely varying load conditions. Figure 23 (zone-valve zoning) and Figure 24 (circulator zoning) show suggested piping for these systems.
  • Page 21 series gas-fired water boiler – boiler manual GV90+ Install water piping (continued) Piping snow melt systems or combination Auto return temp regulation — circulator Figure 25 snow melt/space heating systems zoning Combination snow melt/space heating systems can have return water temperature below 60°F, and the return temperature will fluctuate.
  • Page 22 series gas-fired water boiler – boiler manual GV90+ Install water piping (continued) Water chiller systems Installing GV90+ boiler in system with water Figure 27 chiller Pipe the boiler and water chiller as shown in Figure 27. Install boiler, as shown, so chilled medium is piped in parallel with heating boiler.

  • 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 pri- mary/secondary circuit as shown in the examples in this manual.

  • Page 24: Multiple Boiler Water Piping

    series gas-fired water boiler – boiler manual GV90+ Multiple boiler water piping Easy-Fit® piping installation Maximum connected load per manifold: 1. Main header and Easy-Fit Manifold pipe sizing. ® 2-inch manifold — 450 MBH a. New system — See page 15. 3-inch manifold —...
  • Page 25 – boiler manual GV90+ Multiple boiler water piping (continued) Piping schematic — typical for multiple GV90+ boilers, using Weil-McLain Easy-Fit manifolds Figure 32 Legend — Figure 32 1 Flow/check valve (each boiler) 11 Check valve or backflow preventer, as required by applicable...
  • Page 26 – boiler manual GV90+ Multiple boiler water piping (continued) Piping layout — typical for multiple GV90+ boilers, using Weil-McLain Easy-Fit manifolds (2-boiler system) Figure 33 Legend — Figure 33 1 Flow/check valve (each boiler) 17 3-way diverting valve (operated by DHW aquastat — valve end...
  • Page 27 series gas-fired water boiler – boiler manual GV90+ Multiple boiler water piping (continued) Piping layout — typical for multiple GV90+ boilers, with DHW storage heaters (4-boiler system) Figure 34 Flow rate Size Flow rate Size Suggested DHW 1 – 4 gpm ¾”...
  • Page 28 series gas-fired water boiler – boiler manual GV90+ Multiple boiler water piping (continued) Piping layout — typical for multiple GV90+ boilers, using isolation exchanger Figure 35 Use isolation heat exchanger for: 1. Large volume systems with high mineral content in water. 2.

  • Page 29: Venting & Air - General

    Any improper operation of common venting system should be manufacturers’ components and systems ap- corrected so the installation conforms with the National Fuel proved by Weil-McLain. Follow all instructions Gas Code, ANSI Z223.1/NFPA 54 — latest edition. Correct by provided by the venting component and system re-sizing to approach the minimum size as determined using manufacturer.
  • Page 30 series gas-fired water boiler – boiler manual GV90+ Venting & air — general (continued) Provide combustion air: Combustion air contamination: DIRECT VENT — The installation must provide com- Ensure that the combustion air will bustion air piping. In addition, ventilation openings not contain any of the contaminants may be required.
  • Page 31 series gas-fired water boiler – boiler manual GV90+ Venting & air — general (continued) Manifolded combustion air Combustion air manifold option (combined air inlet, but Figure 37 option for DIRECT VENT individual vents) — must comply with Figure 41, page 35 multiple boiler installations 1.
  • Page 32 When using IPEX kits, use only IPEX product code 196006 for 3” venting. ance all pipe, fittings and cement must be IPEX System 1738. Contact Weil-McLain for ordering information and availability of Weil-McLain venting kits. Polypropylene - Separate pipe and concentric termination by respective manufacturers.
  • 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

    series gas-fired water boiler – boiler manual GV90+ Commonwealth of Massachusetts installations Commonwealth of Massachusetts — When the boiler is installed within the Commonwealth of Massachusetts, the boiler must be installed by a licensed plumber or gas fitter. Read and comply with the instructions below. For all sidewall horizontally-vented .

  • Page 35: Vent Termination Requirements

    series gas-fired water boiler – boiler manual GV90+ Vent termination requirements The vent termination must be located to meet all requirements below (also applies to vertical vent terminations). The minimum distance Figure 41 from adjacent public walkways, adjacent buildings, openable windows and building in the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 - latest edition and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1.

  • Page 36: Direct Vent - Boiler Room Air Openings

    series gas-fired water boiler – boiler manual GV90+ DIRECT VENT — Boiler room air openings Combustion and ventilation air openings for GV90+ Direct Vent installations Figure 42 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: Direct Vent - Sidewall With W-M (Optional) Vent/ Air Plate

    The Weil-McLain plate termination must be installed before Step 7 using the manifolded combustion piping from the boiler to the termination. air option. The vents must be lo-...
  • Page 38 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: Direct Vent - Sidewall With Separate Pipes

    series gas-fired water boiler – boiler manual GV90+ DIRECT VENT — Sidewall with separate pipes Allowable vent/air pipe materials & — Separate pipes sidewall Figure 47 INSTALLATION SEQUENCE lengths Use only the vent materials and kits listed in Figure 40, page 33. Provide pipe adapters if specified.
  • 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. 4. Follow all local codes for isolation of vent pipe when passing through floors or walls.

  • Page 41: Direct Vent - Sidewall With 3" Concentric

    series gas-fired water boiler – boiler manual GV90+ DIRECT VENT — Sidewall with 3” concentric Allowable vent/air pipe materials & — Concentric horizontal Figure 50 INSTALLATION SEQUENCE lengths 1. The 3” concentric termination kit must be pur- chased separately. Use only the vent materials and kits listed in Figure 40, page 33.
  • Page 42 series gas-fired water boiler – boiler manual GV90+ DIRECT VENT — Sidewall with 3” concentric (continued) Install termination — concentric pipes Termination location — concentric Figure 51 1. Assemble the vent termination as described for concentric termi- termination — multiple boilers — clearance nations, on page 47.

  • Page 43: Direct Vent - Vertical With Separate Pipes

    series gas-fired water boiler – boiler manual GV90+ DIRECT VENT — Vertical with separate pipes Allowable vent/air pipe materials & Separate pipes vertical termination Figure 53 lengths Use only the vent materials and kits listed in Figure 40, page 33. Provide pipe adapters if specified. 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...
  • Page 44 series gas-fired water boiler – boiler manual GV90+ DIRECT VENT — Vertical with separate pipes (continued) 3. Space the air and vent holes to provide the minimum spacings Terminations for multiple boilers Figure 54 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: Direct Vent - Vertical With 3" Concentric

    series gas-fired water boiler – boiler manual GV90+ DIRECT VENT — Vertical with 3” concentric Allowable vent/air pipe materials & — Concentric vertical Figure 55 INSTALLATION SEQUENCE lengths 1. The 3” concentric termination kit must be purchased separately. Use only the vent materials and kits listed in Figure 40, page 33.
  • Page 46 series gas-fired water boiler – boiler manual GV90+ DIRECT VENT — Vertical with 3” concentric (continued) Mount concentric termination Vertical termination — 3” PVC concentric — Figure 56 1. Mount the termination as shown in Figure 57, page 46. single or multiple boilers 2.
  • Page 47 series gas-fired water boiler – boiler manual GV90+ Concentric termination assembly (sidewall or vertical) Assembling concentric termination 3” PVC concentric termination assembly — DO NOT Figure 58 attach the rain cap until the termination has been 1. See Figure  58 for the details of the termination inserted through the roof or wall and all supports have assembly.
  • Page 48 AL29-4C stainless vent starter at the boiler vent connection (and at the termination if using the Weil-McLain plate 7. Dry assemble entire vent or air piping to ensure or the concentric termination). Use only the starter made by the proper fit before assembling any joint.

  • Page 49: Direct Exhaust - Boiler Room Air Openings

    series gas-fired water boiler – boiler manual GV90+ DIRECT EXHAUST — Boiler room air openings Special considerations Combustion air provision 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 Z223.1/NFPA 54 - latest edition defines unusually tight vent instructions in this manual.)
  • Page 50 series gas-fired water boiler – boiler manual GV90+ DIRECT EXHAUST — Boiler room air openings (cont.) MINIMUM combustion air openings for direct exhaust applications — ALL OPENING SIZES ARE FREE AREA Figure 60 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 clear- Figure 2, page...

  • Page 51: Direct Exhaust - Sidewall

    External venting greater than 4 feet re- Step 6 The vent piping can terminate using the Weil-McLain vent/air plate (without air piping connected). It can also terminate using a coupling or down-turned quires an enclosure around the vent pipe.
  • Page 52 6 Extend vent pipe through outside plate enough to attach termination coupling (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 — bird screen not required. Part number 550-143-010/1021...

  • Page 53: Direct Exhaust - Vertical

    series gas-fired water boiler – boiler manual GV90+ DIRECT EXHAUST — Vertical Allowable vent/air pipe materials & — Direct exhaust vertical Figure 63 INSTALLATION SEQUENCE lengths Use only the vent materials and kits listed in Figure 40, page 33. Provide pipe adapt- ers if specified. 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...

  • Page 54: Gas Piping

    series gas-fired water boiler – boiler manual GV90+ Gas piping Connecting gas supply piping Figure 64 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: Wiring

    Install 100% lockup gas pressure regulator in sup- To replace wiring, order complete harness assem- ply line if inlet pressure exceeds 14” water column. blies from Weil-McLain. If any original wiring as Adjust for 14” w.c. maximum. supplied with boiler must be replaced, and a har-...
  • Page 56 series gas-fired water boiler – boiler manual GV90+ Wiring (continued) Field wiring connections — service switch and thermostat (or end switch) provided by installer Figure 66 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 series gas-fired water boiler – boiler manual GV90+ Wiring (continued) Figure 68 Ladder wiring diagram Part number 550-143-010/1021...
  • Page 58 series gas-fired water boiler – boiler manual GV90+ Wiring (continued) Schematic wiring diagram Figure 69 Part number 550-143-010/1021...

  • Page 59: Start-Up

    Antifreeze detects water at boiler return pipe less than 40°F. Both internal circulators will run continuously, Use only antifreeze listed by Weil-McLain as suitable for use even with no call for heat, until temperature rises. with GV90+ boilers. Part number 550-143-010/1021...
  • Page 60 Typical cold water fill pressure for a residential system is 12 psi (when using a 30 PSIG boiler relief valve). for Weil-McLain part numbers to obtain antifreeze through b. Pressure will rise when boiler is turned on and system wa- a Weil-McLain distributor.
  • Page 61 series gas-fired water boiler – boiler manual GV90+ Start-up (continued) Inspect/fill condensate system Check for gas leaks Inspect/check condensate lines and fittings Inspect the condensate drain line and the condensate trap. Before starting the boiler, and during initial operation, use a leak detector or smell near the Fill condensate trap with water floor and around the boiler for gas odorant or 1.

  • Page 62: Startup - Final Checks

    series gas-fired water boiler – boiler manual GV90+ 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 ‰...
  • Page 63 series gas-fired water boiler – boiler manual GV90+ Start-up (continued) 5. Position and zero manometer per manufacturer’s instructions. Check for igniter glow by looking into Figure 72 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 series gas-fired water boiler – boiler manual GV90+ Start-up (continued) Final checklist Legend for Figure 74 Use the checklist following to ensure boiler is 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 operating correctly.

  • Page 65: Department Of Energy - Compliance

    series gas-fired water boiler – boiler manual GV90+ Start-up (continued) d. IBC will begin purge cycle, then activate the 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 series gas-fired water boiler – boiler manual GV90+ Start-up (continued) Integrated boiler control (IBC) sequence of operation — status light indications Figure 75 STEPS Call TSTAT PRESS Timing POWER LIMIT FLAME LWCO CIRC SWITCH Heat? (After Step 9, the cycle goes back to Step 1) 1.
  • Page 67 series gas-fired water boiler – boiler manual GV90+ Start-up (continued) Operating instructions Figure 76 Part number 550-143-010/1021...

  • Page 68: Annual Start-Up And General Maintenance Schedule

    series gas-fired water boiler – boiler manual GV90+ Annual start-up and general maintenance schedule Service and maintenance schedules Figure 77 Service technician Owner maintenance (see following pages for instructions) (see following pages for instructions) General: • Address reported problems, page 69. •...

  • Page 69: Annual Start-Up

    series gas-fired water boiler – boiler manual GV90+ 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 The boiler should be inspected and started annu- heat transfer, overheating heat exchanger, and ally, at the beginning of the heating season, only...
  • Page 70 series gas-fired water boiler – boiler manual GV90+ Annual start-up (continued) Inspect expansion tank Figure 78 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 series gas-fired water boiler – boiler manual GV90+ Annual start-up (continued) Inspect temperature mixing system Blower motor Figure 79 1. Carefully check the temperature of the system return as it passes through the boiler jacket and on the piping return pipe inside the boiler jacket just before it enters the boiler sections.
  • Page 72 series gas-fired water boiler – boiler manual GV90+ Annual start-up (continued) Relief valve Figure 80 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: Service & Maintenance

    series gas-fired water boiler – boiler manual GV90+ Service & maintenance Cleaning boiler heating surfaces Blower housing removal procedure Figure 81 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 series gas-fired water boiler – boiler manual GV90+ Service & maintenance (continued) To clean the burner Recuperator access and cleaning Figure 82 The burner may contain ceramic fiber particles. Use care when handling these materials per in- structions on page 106 of this manual.
  • Page 75 8. Use a brush or other means to remove blockage from these holes. 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. Re-install the recuperator 1.

  • Page 76: Troubleshooting

    series gas-fired water boiler – boiler manual GV90+ Troubleshooting VERIFY PROPER OPERATION AFTER Connecting a manometer to check Figure 84 SERVICING. air pressure switch. DO NOT use this arrangement to check gas valve Label all wires prior to disconnection when servicing controls.
  • Page 77 series gas-fired water boiler – boiler manual GV90+ Troubleshooting (continued) Igniter Igniter Figure 85 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 series gas-fired water boiler – boiler manual GV90+ Troubleshooting (continued) Return temperature sensor Supply Temperature/ LWCO sensor 1. See Figure 89. See Figure 91. 2. Resistance check method: 2. The boiler temperature/LWCO sensor is a resistance-type a. With the boiler operating, use a contact thermometer to measure the temperature of the return pipe next to the re- device.
  • Page 79 series gas-fired water boiler – boiler manual GV90+ Troubleshooting (continued) Control indicator lights — Figure 92 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 series gas-fired water boiler – boiler manual GV90+ Troubleshooting (continued) Figure 93 Integrated Boiler Control (IBC)- harness plug receptacle and indicator light locations Part number 550-143-010/1021...
  • Page 81 series gas-fired water boiler – boiler manual GV90+ Troubleshooting (continued) Common causes and possible corrections, part 1 Figure 94 Symptom Common Causes Possible Corrections Rapid cycling — boiler turns Thermostat installed where drafts Locate thermostat on inner wall away from on and off frequently or heat affect reading heat sources or cool drafts.
  • Page 82 series gas-fired water boiler – boiler manual GV90+ Troubleshooting (continued) Common causes and possible corrections, part 2 Figure 95 Symptom Common Causes Possible Corrections Popping or percolating noise Mineral deposits in sections due Call qualified service technician to de- heard in boiler to constant use of makeup water lime boiler, if necessary.
  • Page 83 • Check for 24VAC at R & C terminals on thermostat harness. Does voltmeter indicate 24VAC? 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 550-143-010/1021...
  • Page 84 series gas-fired water boiler – boiler manual GV90+ Troubleshooting (continued) TSTAT/CIRC & POWER lights flashing CHART 2 Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to fol- low instructions could result in severe personal injury, death or substantial property damage. Is return water temperature sensor clamped •...
  • Page 85 series gas-fired water boiler – boiler manual GV90+ Troubleshooting (continued) PRESS SWITCH & POWER lights flashing CHART 3 Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to fol- low instructions could result in severe personal injury, death or substantial property damage. •...
  • Page 86 Are FLAME & POWER lights flashing? • Boiler should now operate normally. • Original flashing FLAME light caused by gas valve not operating properly. • See normal sequence of operation (Fig- • Call your local Weil-McLain ure 75, page 66). sales representative. Part number 550-143-010/1021...
  • Page 87 series gas-fired water boiler – boiler manual GV90+ Troubleshooting (continued) TSTAT/CIRC light flashing and POWER light on steady CHART 5 Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to fol- low instructions could result in severe personal injury, death or substantial property damage. •...
  • Page 88 series gas-fired water boiler – boiler manual GV90+ Troubleshooting (continued) LIMIT light flashing and POWER light on steady CHART 6 Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to fol- low instructions could result in severe personal injury, death or substantial property damage. •...
  • Page 89 series gas-fired water boiler – boiler manual GV90+ Troubleshooting (continued) Insufficient heat or no heat to system (POWER light on steady) CHART 7 Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to fol- low instructions could result in severe personal injury, death or substantial property damage. •...

  • Page 90: Installation And Service Certificate

    series gas-fired water boiler – boiler manual GV90+ Troubleshooting (continued) Troubleshooting LWCO and POWER light Solid CHART 8 and/or “LCO” shown on display Electrical shock hazard — Wherever you see TURN OFF POWER, follow the instructions. Failure to fol- low instructions could result in severe personal injury, death or substantial property damage. Is boiler pressurized? •...

  • Page 91: Replacement Parts

    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: 592-900-006 Antifreeze, aluminum-safe, Sentinel X500 ..... . .
  • Page 92 Replacement parts (continued) Section assembly Figure 97 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 silicone sealant, tie rods, tie rod nuts, tie rod washers, blower flange...
  • Page 93 series gas-fired water boiler – boiler manual GV90+ Replacement parts (continued) Section assembly Figure 98 Part number 550-143-010/1021...
  • Page 94 – boiler manual GV90+ Replacement parts (continued) Jacket assembly Figure 99 Item Description Model Weil-McLain number part number 3 & 4 382-200-758 Jacket panel, top 5 & 6 382-200-759 Jacket panel, front 382-200-751 382-200-752 382-200-753 Jacket panel, left side, front...
  • Page 95 series gas-fired water boiler – boiler manual GV90+ Replacement parts (continued) Jacket assembly Figure 100 Part number 550-143-010/1021...
  • Page 96 – boiler manual GV90+ Replacement parts (continued) Figure 101 Blower assembly Item Description Model Weil-McLain number part number Burner replacement kit, includes burner, blower flange gasket, igniter, igniter 382-200-320 screws, igniter washers, igniter gasket 382-200-325 382-200-330 382-200-335...
  • Page 97 series gas-fired water boiler – boiler manual GV90+ Replacement parts (continued) Blower assembly Figure 102 Part number 550-143-010/1021...
  • Page 98 – boiler manual GV90+ Replacement parts (continued) Trim assembly Figure 103 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 series gas-fired water boiler – boiler manual GV90+ Replacement parts (continued) Trim assembly Figure 104 Part number 550-143-010/1021...
  • Page 100 – boiler manual GV90+ Replacement parts (continued) Interior panel Figure 105 Item Description Weil-McLain number part number Interior panel Figure 99, page item 8 Integrated boiler control assembly, includes IBC and screws 381-330-044 Transformer 381-356-578 Air pressure switch...
  • Page 101 series gas-fired water boiler – boiler manual GV90+ Replacement parts (continued) Figure 106 Interior panel Part number 550-143-010/1021...

  • Page 102: Dimensions And Ratings

    series gas-fired water boiler – boiler manual GV90+ Dimensions and ratings Dimension drawing (see Figure 108, page 103 for dimensional table) Figure 107 Item Description number 1” NPT Supply 1” NPT Return Combination pressure-temperature gauge, 2 ½” short shank ¾” NPT Relief valve outlet Plug dome, 2”...
  • Page 103 series gas-fired water boiler – boiler manual GV90+ Dimensions and ratings (continued) Boiler dimensional and physical data (see Figure 107, page 102) Figure 108 Supply Return Electrical Boiler Approx. Length Boiler connection service water shipping model size required content weight (Note 1) (includes the internal...
  • 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 Vent piping cannot be manifolded terminate vents as described in vent/air installation instructions in this manual.
  • Page 105 series gas-fired water boiler – boiler manual GV90+ Dimensions and ratings (continued) Figure 111 Engineering data — see page 103 for additional technical information Water flow rate per boiler Vent/air pipe size — Provide a separate vent Boiler for each boiler Model GPM @ 20°F rise GPM @ 40°F rise...

  • Page 106: Handling Ceramic Fiber And Fiberglass Materials

    series gas-fired water boiler – boiler manual GV90+ Handling ceramic fiber and fiberglass materials HANDLING CERAMIC FIBER REMOVAL OR INSTALLATION MATERIALS OF FIBERGLASS WOOL 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 series gas-fired water boiler – boiler manual GV90+ NOTES Part number 550-143-010/1021...
  • Page 108 series gas-fired water boiler – boiler manual GV90+ Part number 550-143-010/1021...

This manual is also suitable for:

Gv90+Gv90+3Gv90+4Gv90+5Gv90+6Gv90 plus

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