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Part number 550-142-903/1016

Series 2

Gas-Fired Water Boilers

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.

• Installation

• Startup

• Maintenance

• Parts

Boiler Manual

Beginning Serial Number:

CP7538624

How It Works2
Legend2
GV90+ Series 23
Contents4
Hazard Deﬁnitions4
Please Read before Proceeding5
Prepare Boiler Location6
Installations Must Follow These Codes6
High Altitude Installations6
Flooring6
Service Clearances6
Foundation7
Residential Garage Installation7
Minimum Clearances7
Minimum Foundation Dimensions7
Prepare the Boiler8
Check Oriﬁce Plate8
Natural Gas/Propane8
Orifice Plate Installation8
Install Condensate Trap9
GV90+ Suggested Condensate Pump Capacity9
Finished Assembly9
Install High Altitude Air Pressure Switch When Required10
Rotate the Boiler into Position10
Air Pressure Switch Mounting10
Perform Hydrostatic Pressure Test11
Prepare Boiler for Test11
Fill and Pressure Test11
Drain and Remove Fittings11
Install Water Piping12
General Piping Information12
Additional Limit Controls12
Install Relief Valve12
Expansion Tank13
Diaphragm or Bladder-Type Tank13
Closed-Type Expansion Tank13
Relief Valve Installation Guidelines13
Piping to Single-Zone System14
Piping Closed-Type Expansion Tank14
System Water Piping Methods15
Circulators15
Simpliﬁed Pipe/Circulator Selection15
Circulator Flow Rate15
Baseboard System Piping — CIRCULATOR Zoning16
ZONE VALVE Zoning16
One-Pipe Diverter Tees Systems17
The System Must Meet the Following Requirements17
Radiator System Piping18
Radiator System — Zone-Valve Zoning18
Circulator Zoning18
Single-Zone Radiant Heating or Heat Pump19
Adjust Balancing Valves19
Single-Zone Radiant Heating or Heat Pump System19
Multi-Zone Radiant Heating System20
Outdoor Reset20
Auto System Supply Temp Regulation20
Piping Snow Melt or Combination Snow Melt/Space Heating Systems21
Auto Return Temp Regulation21
Water Chiller Systems22
Installing GV90+ Boiler in System with Water Chiller22
Multiple Boiler Installations23
Placing Multiple Boilers23
Controlling Multiple GV90+ Boilers23
Piping Multiple GV90+ Boilers23
Easy-Fit Piping Installation24
Single-Sided EZ-Fit Header Connection24
Double-Sided EZ-Fit Header Connection24
Multiple Boiler Water Piping24
Piping Schematic25
Piping Layout26
Venting and Air — General29
When Removing a Boiler from an Existing Common Vent System29
Vent System Verification29
Existing Vent Test Procedure29
Vent and Air Termination Options30
DIRECT VENT Installations30
DIRECT EXHAUST Installations30
Provide Combustion Air30
Manifolded Combustion Air Option for DIRECT VENT Boiler Installations31
Air Manifold Sizing31
Combustion Air Manifold Option31
Maintain Clearances and Placement between the Air Manifold Inlet31
GV90+ Venting and Air Piping32
Vent and Air Piping Materials33
Commonwealth of Massachusetts Installations34
Installation of Carbon Monoxide Detectors34
Signage34
Inspection34
Vent Termination Requirements35
Do Not Terminate35
Consider35
Direct Vent — Boiler Room Air Openings36
Combustion and Ventilation Air Openings36
Sidewall with W-M Vant/Air Plate37
Allowable Vent/Air Pipe Materials and Lengths37
Determine Termination Location37
Multiple Vent/Air Terminations37
Install Weil-Mclain Vent/Air Cap38
Multiple Terminations38
Hole Preparation in Wall38
Termination Assembly38
Sidewall with Separate Pipes39
Installation Sequence - Separate Pipes Sidewall39
Prepare Wall Penetrations40
Termination and Fittings40
Multiple Separate Pipes Sidewall Terminations40
Sidewall Termination Assembly — Using Separate Pipes40
Sidewall with 3" Concentric41
Concentric Horizontal41
Install Termination - Concentric Pipes42
Termination Location42
Installing and Supporting the Concentric Sidewall Vent Assembly42
Vertical with Separate Pipes43
Allowable Vent/Air Pipe Materials and Length43
Prepare Roof Penetrations43
Separate Pipes Vertical Termination43
Termination and Fittings44
Terminations for Multiple Boilers44
Vertical with 3" Concentric45
Concentric Vertical45
Mount Concentric Termination46
Vertical Termination46
3” PVC Concentric Termination Supports46
Concentric Termination Assembly47
Assembling Concentric Termination47
3” PVC Concentric Termination Assembly47
Vent and Air Piping and Boiler Connections48
Direct Exhaust and Direct Vent48
Direct Exhaust Only48
Installing Vent and Air Piping48
Boiler Room Air Openings49
Combustion Air Provision49
Sizing Combustion Air Openings49
Special Considerations49
Minimum Combustion Air Openings for Direct Exhaust Applications50
Sidewall51
Direct Exhaust Sidewall51
Direct Exhaust52
Vertical53
Direct Exhaust Vertical53
Gas Piping54
Connecting Gas Supply Piping54
Gas Supply Connection to GV90+ Boiler Gas Manifold54
Wiring55
Natural Gas55
Propane Gas55
Wiring Connections55
Wiring Multiple Zones56
Carbon Monoxide Detector56
Dhw56
R and C Connections56
Ladder Wiring Diagram57
Schematic Wiring Diagram58
Clean System to Remove Sediment59
Water Chemistry59
Antifreeze59
Freeze Protection Guidelines59
Purge Air from Water System60
Pressure System60
Use Inhibitor Supplied with Boiler60
Check Inhibitor Concentration Annually60
Verify Gas/Air Oriﬁce Plate61
Check Thermostat Circuit61
Inspect/Fill Condensate System61
Check for Gas Leaks61
Final Checks before Starting Boiler62
Adjust Boiler Control Settings62
Boiler Economy Setting62
Check System and Boiler after Start-Up62
Gas Valve Adjustment — Altitude over 5,500 Feet63
Connect and Adjust Manometer63
Check Gas Valve Setpoint63
Check Gas Piping/Igniter63
Final Checklist64
Have the Following Been Completed?64
Perform the Following64
Carefully Connect Manometer to Gas Valve as Shown64
Department of Energy – Compliance65
Integrated Boiler Control Sequence of Operation66
Operating Instructions67
Precautions67
What to Do if You Smell Gas67
To Turn off the Gas to the Appliance67
Annual Start-Up and General Maintenance Schedule68
Service and Maintenance Schedules68
Inspect Boiler Area/Interior69
Inspect Condensate Drain System69
Inspect the Water System69
Check Water System Chemistry69
Address Reported Problems69
Inspect Expansion Tank70
Inspect Air Openings70
Inspect Vent System and Air Piping70
Inspect Boiler Heating Surfaces70
Inspect Temperature Mixing System71
Inspect Additional Controls and Cutoffs71
Inspect Blower Motor71
Inspect Temperature Sensor71
Inspect Boiler Relief Valve72
To Complete Annual Start-Up72
Review with Owner72
Relief Valve72
Service and Maintenance73
Cleaning Boiler Heating Surfaces73
To Remove the Blower Assembly73
To Clean Heating Surfaces73
To Clean the Burner74
To Replace Blower Assembly74
Inspecting and Cleaning the Recuperator74
Removing/Cleaning/Re-Installing the Recuperator74
Re-Install the Recuperator75
Re-Install the Condensate Trap75
Re-Connect the Vent Pipe75
Recuperator Flueway Drain Holes75
Troubleshooting76
Before Troubleshooting76
Checking the Air Pressure Switch76
Check Switch Pressure Setting76
Igniter77
Gas Valve77
Blower Housing77
Thermal Fuse77
Return Temperature Sensor78
Supply Temperature Sensor78
Return Temperature Sensor Resistance78
Table Sensor Resistance Values78
Ibc79
IBC Indicator Lights — Lockout Modes79
Control Indicator Lights79
IBC Indicator Lights — Non-Lockout Modes79
IBC Harness Plug Receptacle and Indicator Light Locations80
Common Causes and Possible Corrections81
Troubleshooting Power Light Status83
TSTAT/CIRC and Power Lights Flashing84
Press Switch and Power Lights Flashing85
Flame and Power Lights Flashing86
TSTAT/CIRC Light Flashing and Power Light on Steady87
Limit Light Flashing and POWER Light on Steady88
Insufﬁcient Heat or no Heat to System89
Troubleshooting Sensor Ground and Power Light Solid90
Replacement Parts91
Miscellaneous Parts91
Section Assembly92
Jacket Assembly94
Blower Assembly96
Trim Assembly98
Interior Panel100
Dimensions and Ratings102
Boiler Dimensional and Physical Data103
Boiler Ratings103
Multiple GV90+ Boilers104
Engineering Data105
Handling Ceramic Fiber and Fiberglass Materials106

Brand	Weil-McLain
Model	GV90+
Category	Boiler
Language	English

Weil-McLain GV90+ User Manual

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