Table Of Contents - Weil-McLain GV90+ Installation And Start-Up Manual

GV90+ Se ries 2
oAs·FIRED WATER BOILER -
Boiler Manual
Contents
How it
works ..... .
GV90+ Wat er Boiler .
.2
.3
Pie
a M
read belore p~eding
. . . 5
Prepare b oilerlocation . . . . . . . 6
Installations mu.<n fonow these codes: . . . 6
High
altitude
i:nstallatfons . . . . . . . . . . 6
Residential garage installation . . . . . . .
1
Check orifice plate - replace
if
necessary . 8
Install condensate uap. . . . . . . . . . . . 9
Install high altitude air pr essure switch when
required {onJy above S.SSO
feet) . . . . . .
9
Rotate the boiler into position . . . . . . 1 0
Perform hydrostatic pressure
test . . . . .
II
Install water piping . . . . . . . . 12
General pipi:ng in formation . . . . . . . . 12
Install reliefvah-e . . . . . . . . . . . . . 12
Expansion tank • . . . . . . . . . . . . . . 13
System water piping methods . . . . . . . IS
Orculators . . . . . . . . . . . . . . . . . IS
Simplified pipe/cirrulator selection ... IS
Baseboard system piping - ORCULATOR
'ZOning (pri:marylseconcfary) . . . . . . . 16
Baseboard system piping - ZONE VAL VE
'ZOning (direct connection) . . . . . . . . 1 6
Radiator system piping . . . . . . . . . .
18
Single·wne radiant heati:ng or heat pump
1 9
Ad;wt
balancing vah<S , , , , , , , , , , 1 9
Multi·wne radiant heatiog system . . . .
20
Piping snow melt systems or combination
snow
melt/space heating ;Systems. . . . . 2 1
Water ch iller systems . . . . . . . . . . .
22
Multiple boiler inst allations . . . . 23
Placing multiple
boi~s
. . . . . . . . . .
23
Conu olling multiple CV90+ boilers . . .
23
Piping multiple CV90+ boilers. . . . . .
23
Multiple boiler water piping • . . . 24
Easy·Fit• piping installation . . . . . . . 24
Venting & air - genKal . . . . . . 29
When removing a boiler from an existing
common vent system . . . . . . . . . . . 29
Existing vent test procedure . . . . . . . .
29
Provide combustion
air: . . . . . . . . . .
30
Vent and air termination options . . . . . 30
DIRECfVENTinstallations . . . . . . . 30
DIRECT EXHAUST installations . . . . . 30
Combustion air contamination: . . . . . 30
Manifolded combustion air option
(or
Dl·
RECT VENT multiple boib inslallations. . .
3 1
Air manifold sizing . . . . . . . . . . . . 3 1
Commonwealth of Mllssaohusetts
installations . . . . . . . . . . . . 34
Vent termination requirements .. 35
DIRECT VENT - Boil er room air
openings . . . . . . . . . . . . . . 36
DIRECT VENT - Sidewall with W -M
ventfair plate . . . . . . . . . . . . 37
DIRECT VENT - Sidewall with oepa·
rate pipes . . . . . . . . . . . . . . 39
4
DIRECT VENT - Sidewall with
3"
concentric . . . . . . . . . . . . . 41
DIRECT VENT - Vertical with - ·
rate p ipes . . . . . . . . . . . . . .
43
DIRECT VENT - Vertical with 3"
concentric . . . . . . . . . . . . .
45
Concentric termination
assembly
(sidewall o r vertical) . . . . . . . . 47
Vent and a ir p iping and boiler con-
n ections . . . . . . . . . . . . . .
48
DIRECTEXHAUST&DIRECTVENT . 48
Follow termination instructions . . . . .
48
Installing vent and air piping . . . . . . .
48
DIRECT EXHAUST ONLY . . . . . . . . 48
DIRECT EXHAUST - Boiler room air
openings . . . . . . . . . . . . . .
49
Combustion ai:r provision. . . . . . . . . 49
Siring combu.<Jtion air openings . . . . .
49
Special constderations . . . . . . . . . . .
49
9V90+ boiler WITHOUT other appliances
tn room . . . . . . . . . . . . . . . . . . .
50
Air openings . . . . . . . . . . . . . . . . 50
CV90+ boiler WITH other appliances in
roon1 . . . . . . . . . . . . . . . . . . . . 50
DIRECT EXHAUST - Sidewall .. 51
DIRECT EXHAUST - Vertical •.. 53
Gas piping . . . . . . . . . . . . . 54
Connecting
gas
suppty pi ping. . . . . . .
S4
Natural Cas . . . . . . . . . . . . . . . . .
SS
Propane Cas . . . . . . . . . . . . . . . .
SS
Wiring . . . . . . . . . . . . . . . 55
Field wiring. . . . . . . . . . . . . . . . . S6
Start-up . . . . . . . . . . . . . . . 59
Freeze protection (when u.W) . . . . . . S9
Clean system to remo\>e sediment . . . .
S9
Water chemistry . . . . . . . . . . . . . .
S9
Antifreeze . . . . . . . . . . . . . . . . . .
S9
Flll and test wa.ter system . . . . . . . . . 60
Use inhibitor supplied with boiler . . . . 60
Check/Verify water chemistry. . . . . . . 60
Check
imllit:or c.oncmtnr:ion anrualy . . . 60
Check for
gas
leaks. . . . . . . . . . . . . 61
Verifygas/airorificeplate . . . . . . . . .
61
Check thermostat circuit(s) . . . . . . . . 61
Inspect/fiJI condensate system . . . . . .
61
Final checks before starting boiler . . . . 62
Adjust boiler control
srttinp . . . . . . .
62
Aju.•n boiler control setti:nSJ> . . . . . . . . 62
Boiler Economy settings. . . . . . . . . . 62
To start
the
boiler . . . . . . . . . . . . . 62
If boiler does notstart correctly . . . . . 62
Check system and boiler after start·up .. 62
Cas vatve adjustment - attitude
O\'ft'
S.SOO
re.tONLY . . . . . . . . . . . . . . . . . 63
Final checklist . . . . . . . . . . . . . . . 64
Department of
Energy
eon-.>liance .
65
IBC (Sequence of operations) . . . . . . . 66
Operating lnstrustions . . . . . . . . . . 67
Annual start·up a nd general mainte-
na nce schedule . . . . . . . . . . 68
Annual start-up . . . . . . . . . . 69
Address reported problems . . . . . . . .
69
Inspect boiler area . . . . . . . . . . . . . 69
Inspect boiler interior . . . . . . . . . . .
69
Inspect condensate drain syste:nl . . . . . 69
Inspect all piping for leaks . . . . . . . .
69
Inspect gas piping . . . . . . . . . . . . .
69
Inspect
the
water system. . . . . . . . . .
69
Check water syste:nl chemistry . . . . . . 69
Inspect expansion tank . . . . . . . . . . 70
Inspect air openings . . . . . . . . . . . . 70
Inspect vent system and air piping . . . . 70
Inspect boiler heating
surfaces . . . . . .
70
Inspect igniter . . . . . . . . . . . . . . . 70
Inspect te:nlpe:ral'Ute mi.xi:ng system . . . 71
Inspect additional conuok and cutotfs . . .
71
Inspect gauge5 . . . . . . . . . . . . . . . 71
Inspect blower motor . . . . . . . . . . . 71
Inspect oiled·beari:ng circulaton . . . . . 71
Inspect supply temperature sensor . . . . 71
Inspect boiler relief valve . . . . . . . . .
n
To comple1< Annual Slan·up, perform
startup and checks . . . . . . . . . . . .
n
Review with
owner. . . . . . . . . . . . .
n
Service
&
mainte nance . . . . . .
73
Cleaning boiler heating
surf:lces . . . . .
73
To remove the blower assembty . . . . .
73
To dean heating surfaces . . . . . . . . .
73
To dean
the burner . . . . . . . . . . . . 74
To replace blower assembly . . . . . . . .
74
Inspecting and deaning
the
recuperator
74
Tro~ esh ooting
. . . . . . . . . . 76
VERIFY PROPER OPERATION AFTER
SERVICING . . . . . . . . . . . . . . . . . 76
Before troubleshooting . . . . . . . . . .
76
Check the following . . . . . . . . . . . .
76
Checking the air pressure switch . . . . . 76
Igniter . . . . . . . . . . . . . . . . . . . . 77
Gas Valve . . . . . . . . . . . . . . . . . . 77
Blower Housing . . . . . . . . . . . . . . 77
Thermal fuse . . . . . . . . . . . . . . . . 77
Return
temperature sensor . . . . . . . . 78
Suppty temperature sensor . . . . . . . . 78
IBC (integrated boiler control)
. . . . . . 79
IBC indKator Lights - lockout modes. . 79
IBCin<iiolt« liglu> - non·~m<><l<!
. 79
Installation a nd service
certificate . . . . . . 90
Replacement parts . . . . 91
Dimensions and ratings . 102
Handling ceramic fiber and fiber-
glaoo mate rials. 106
NOTES . . . . . . . . . . . . . . 107
Pan number
SS0-142· 783/1012