Weil-McLain GV90+ Installation and operation manual

®
• Installation
• Startup
• Maintenance
• Parts
Boiler Manual
Series 2
Gas-Fired Water Boilers
Thismanualmustonlybeusedby a qualified heating installer/servicetechnician.BEFOREinstalling,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.
Part number 550-142-783/1012

GV90 + Series 2 oAs·FIRED WATER BOILER - Boiler Manual
How it works •••
1 Integrated boilercontrol
The integrated boiler control (IBC) responds to signals from the room thermostat, air
pressureswitdl,i :n letwatersensor,boiler wa .ter temperaturesensorandboilerlimitcircuit
to operate the circulators, gas valve, igniterandbl ower. Whena room thermostat ca Us
for heat, th e I BC star ts the sys tem circulatorandblower.
The JB C runs the bi O'\\• er to purge the boiler flue passages, then turnson th e igniter and
lets itwarm up.
Aft er igniterwarm· up , th e I DC opens the gas vah-e, rurnstheigniteroff, and checksfor
flam e. Th e flam e must come on within 4wconds or the me willshut down and try the
fu ll cydeagain.
W
hen the room thermostat is satisfied. the IB C turns off the boilercomponents and
wa i.ts (or the next beat ca ll .
The IBC in dicator lig h. ts shownonnalsequence wh en th e lightsare on steady. When a
problem occurs, the JB C flashes combinations of lights whichindica te the most bkel y
reason for theproble m..
Wh ileattempting to satisfy the heat demand, the con tr ol module m oni t ors the boiler
temperature changes via the temperature sensors a nd determ in es wh eth er or not t he
ava il ab le hot water w. tll satisfy th e de mand, only ru nning the ci: rculator. Ifadditional
heat is needed, the sequence
co n ti: n ues.. When DHW (if used) caJJs fo r heat. sequen ce
aboveisbypassed.
2 Transformer
The controltransfo rm er reducesline vottage to 24 voltsforthe gas valve andlimit ci:rc ui t.
3 Blower
The blower pulls i: n ai: r and mi xes it with gas &om th egas valve. Thebla\\'et forces this
m ixturt in to lhe burner fo r co ml xu:tio nin side- the- bo il er ch amber.
4 Recuperator
Therecupenttor is a stainless steel beat ex chang er that increasesboaere fficiency byex·
trading additionalbeat &omthefluega ws, Return waterpasws throughtherecuperator
beforeentering theboiler.
5 Water temperature sensor
The wat~r t~mptra l u r ~ se n sor provides a signal to the conrrol modu le to turn
off rhe gas va l v~ if the temprratur~ in the boiler goes abo~ its setring. (The
circulator wlll
co nrinue to run aslong asthere isa call for heat.)
6 System circulator
The sy stem circulatorcirculates water throughtheexternal (S) 'Stem) piping, The flow
ra . te of th ecirculator i:s controlled by the IBC, depend in gonthetemperatu re of th e wa t er
en t er in g t he bo il er .se<tio n $. Pump m u.< n rema in on boiler- do not remove.
7 Bypa .. circulator
The IBC operates the bypass ci rc ul ator to mi.x hot water fro m t he boil er outlet with
colderreturn "'ater from the S) 'Stem as needed to preventcondensation of flue gas es in
th e cast iron heatexchanger.
Whe n the wa t er returning to th e boiler Is below IW F. th e I BC reg ul ate$ the bypass ci: r·
culatorand
sy stemcirculator flow rates to rai se the return watertemperature up to l4 0'" F
beforeitenters the cast ironsections, Bybalancing these
flow rate s. the IB Ccanprotect
agai: n .st condensation in the cas tironheatexchangere\'enif return water Is aslowas 6Cr f.
Pump mU$ t re mainon boil er - do not re m m-e.
8 Air pre .. ure switch
The ai:r pressureswitchsignals the IBC.teU ing th e controlwhetherairismoving through
th e blower.
9 Return water temperature sensor
2
The water temperat UI'e sensor mo ni tors the temperatu re of th e wa t er entering the boiler
sectfons.Thesensorsendsthis Information to the IBC .The I BC det er mines how m uch
to adjust the cirrulator fl O\\' rates to provide at least 14 0'" Pwater to thecast iron beat
exchanger.
LE G EN D
a Supply to
system> 1"' NPT
b R etu rn from system, I" NPT
c Combustion air lnle t fit ting -
3"' P VC connecti on
d FJ ue ou tl et - 3"' PVC conn tc ·
tion
e Gas va J ve - negati ve p r ~ss urt
regulated gas control
I Pressure/temperaturegauge
g
FJueway inspection port CO\ ' tr
h Stnsor hosetrap
Manual airvtnt
Rel i ef vaJ\·t
k Thermal fuse- a one·timefuse
de v ice thatshutsboileroff if flue
te:mptratureexceeds irs strpo int
m Condtnsate trap line -sh ipped
loose with boiler,
field installed
n Condensatedraincon nection-
W' PVC female
Thi s boiler uses a negarive· prtssurt -
r
tgu l attd gas valve, ser for an ou tl et
pressure
ap pr oxi ma tely -0 . 20"' water
co l umn .
00 NOT set rhe outle t p r ~ssurt higher
t
ha n factory sett ing.
Pan number55 0- 142-783/1012

GV90+ Series 2 GAS·FIRED WATER BOILER - Boiler Manual
GV90+ Series 2 Water Boiler
Part num ber 55 0- 14-2 -783/1012 3

GV90+ Se ri es 2 oAs·FIRED WATER BOILER - Boiler Manual
Contents
How it works ..... .
GV90 +Water Bo il er .
.2
.3
Pie aM read belore p~eding ... 5
Pr epa re bo il e rl ocat ion ....... 6
Installationsm u.< n fonow thesecodes: ... 6
Highaltitude i: nstallatfons .......... 6
Residential garage installation ....... 1
Check orifice plate-replace if necessary. 8
Installcondensate ua p. . . ......... 9
Install h igh altitude air pr ess ureswitchwh en
required {o nJ yabove S.SSO feet) ...... 9
Rotate t he bo il er in to position ...... 10
Perform hydrostatic pressure t
est ..... II
In sta ll w ate r pip in g ........ 12
General pipi: ng informat ion ........ 12
Install re liefvah-e ............. 12
Exp ansion tank •.............. 13
Sys tem wa ter piping m eth ods ....... IS
Orcula t ors ................. IS
Simplified pipe/cirrulator selection ... IS
Baseboardsystem piping -ORCULATOR
'ZOning (p ri :m arylseco ncf ary ) ....... 16
Baseboardsystem piping - ZO NE VA L VE
'ZOning (d irectconnection) ........ 16
Radiatorsystem piping .......... 18
Single· wne radiant h eati: ng or heat pum p 19
Ad;wt b ala n ci ng vah<S , , , , , , , , , , 19
Multi· wne radiant heatiog system . . . . 20
Pipingsnow meltsystems or combinati on
snow melt/space heating ;Systems. . . . . 2 1
Water chillersystems . . . . . . . . . . . 22
Multiple boiler i ns ta ll at ions .... 23
Placing mul tiple boi~s . . . . . . . . . . 23
Conuollingm ul tipleCV90+ bo il ers . . . 23
Pipingm ul tipleCV90+ boil ers. . . . . . 23
Multiple boiler water pip in g •... 24
Easy ·F it• piping installation . . . . . . . 24
Venting & air- ge n Ka l ...... 29
When removinga boiler from an existing
common ven tsystem . . . . . . . . . . . 29
Existingvent tes t procedure ........ 29
Provi de combustion air: .......... 30
Ven t and air termination options ..... 30
DIRECfVENTinstallations
....... 30
DIRECT
EXHAUST installations ..... 30
Combust
io n air contamination: . . . . . 30
Ma nifoldedcombustion air option (or Dl ·
RECT VENT m ultiple boib inslallations . . . 3 1
Air manifold sizing . . . . . . . . . . . . 3 1
Co mm o nwe alth ofMlls sao h usetts
in sta llati ons . . . . . . ...... 34
Vent te rmination requiremen ts .. 35
DIR EC T VE NT - Bo il er r oo m air
ope nings . . . . . . . . ...... 36
DIR EC T VE NT - Sidewa ll with W-M
ve ntfairplate. . . . . . ...... 37
DIR EC T VE NT - Sidewa ll with oepa·
r
ate pi pe s. . . . . . . . ...... 39
4
DIR E CT VE NT - Sidewa ll with 3"
co n ce nt ri c ............. 41
DIR E CT VE NT - Verti ca l with -·
rate pi pes .............. 43
DIR E CT VE NT - Verti ca l with 3"
co n ce ntric ............. 45
Concentric te rmination assem bly
(sidewa ll or vertica l) ........ 47
Ve nt and a ir pipi ng and boiler co n-
n ec tions .............. 48
DIRECTEXHAUST&DIRECTVENT . 48
Follow terminationinstructions . . . . . 48
Insta ll ingvent a nd air piping . . . . . . . 48
DI RECT EXHAUST ONLY . . . . . . . . 48
DIR E CT E XHAU ST - Boiler r oo m air
ope nings .............. 49
Combustion ai: r provisi on . . . . . . . . . 49
Siring combu.<Jtio n air openings . . . . . 49
Specialconstderations. . . . . . . . . . . 49
9V90+ bo il er WITHOUTother ap pl iances
tn room. . . . . . . . . . . . . . . . . . . 50
Air openings . . . . . . . . . . . . . . . . 50
CV90+ bo il er WITH o th er appliancesin
roon1 . . . . . . . . . . . . . . . . . . . .
50
DIR E CT E XHAU ST - S id ewa ll .. 51
DIR E CT E XHAU ST - Ve rti ca l •.. 53
Gas piping ............. 54
Connecting gas supptypiping. . . . . . . S4
NaturalCas. . . . . . . . . . . . . . . . . SS
PropaneCas . . . . . . . . . . . . . . . . SS
Wiri ng ............... 55
Field wiring. . . . . . . . . . . . . . . . . S6
Sta rt- up ............... 59
Freeze protection(wh en u.W) . . . . . . S9
Cl ea n system to remo\>e sed im ent . . . . S9
Wa t er chemistry . . . . . . . . . . . . . . S9
Antifreeze. . . . . . . . . . . . . . . . . . S9
F lll and test wa .ter system . . . . . . . . . 60
Use inhibit or sup pl ied with bo iler . . . . 60
Check/Ve
ri fy wa ter chemist ry . . . . . . . 60
Check imllit:or c.oncm tnr: ion an rualy . . . 60
Checkfor
gas leaks. . . . . . . . . . . . . 61
Verifygas/airorificeplate . . . . . . . . . 61
Checktherm os tatcircuit(s). . . . . . . . 61
In spect/fiJI condensatesyst em . . . . . . 61
Finalchecks beforestartingboiler . . . . 62
Adjustboiler controlsrttinp . . . . . . . 62
Aju.• n boiler cont ro l setti: n SJ> . . . . . . . . 62
Bo iler Eco nomysettings. . . . . . . . . . 62
To st
art the bo il er ............. 62
If boilerdoes nots tartcorrectly ..... 62
Ch eck system and boilerafterstart ·u p .. 62
Cas vatve adjust me nt- attitude O\'ft' S.SOO
re.tONLY ................. 63
Finalchecklist ............... 64
Departmentof Energy eon-.>liance . 65
IBC (Sequence of operations) ....... 66
Operating lnstrustions .......... 67
Annual st art·up a nd ge neral maint e-
nance sc hedule . . . . . . . . . . 68
Annual st art-up . . . . . . . . . . 69
Address reported problems . . . . . . . . 69
Inspect boilerarea . . . . . . . . . . . . . 69
Inspect boiler in terior . . . . . . . . . . . 69
Inspect condensate drainsyst e:n l . . . . . 69
Inspect all pipi ng for leaks . . . . . . . . 69
Inspectgas piping . . . . . . . . . . . . . 69
Inspect the watersystem. . . . . . . . . . 69
Check watersyst e:n l chemist ry . . . . . . 69
Inspectexpansion tank . . . . . . . . . . 70
Inspect air openings . . . . . . . . . . . . 70
Inspect ven tsystem andair piping . . . . 70
Inspectboil er heati ng surfaces . . . . . . 70
Inspectig ni ter . . . . . . . . . . . . . . . 70
Inspectt e:n l pe:ral'Ute mi.xi: ng system . . . 71
Inspect additional conuok and cutotfs . . . 71
Inspect gauge5 . . . . . . . . . . . . . . . 71
Inspectblower mot or . . . . . . . . . . . 71
Inspectoiled·beari:ng circulaton . . . . . 71
Inspectsupplytemperaturesensor. . . . 71
Inspectboiler relief valve . . . . . . . . . n
To comp l e1< An n ua l Slan·up, perform
startup and checks . . . . . . . . . . . . n
Review with owner. . . . . . . . . . . . . n
Se rvi ce & maintenan ce . . . . . . 73
Cleaning boil er heati ng surf:lces . . . . . 73
To re move theblower assembty . . . . . 73
To dea n heatingsurfaces . . . . . . . . . 73
To dea n the burner . . . . . . . . . . . . 74
To replace blower assembly ........ 74
Inspecting an d dea n ing therecuperator 74
Tro~ es h oo ting .......... 76
VERIFY PROPER OPERATION AFTER
SERV ICING ................. 76
Before troubleshooting . . . . . . . . . . 76
Check the following . . . . . . . . . . . . 76
Checkingtheair pressure switch . . . . . 76
Ig niter .................... 77
Gas Valve . . . . . . . . . . . . . . . . . . 77
Blower Housi ng . . . . . . . . . . . . . . 77
Thermal fuse . . . . . . . . . . . . . . . . 77
Returntemperaturesensor . . . . . . . . 78
Supptytemperaturesensor . . . . . . . . 78
IBC (integrated bo ilercontrol) . . . . . . 79
IBC indKat or Li ghts-lockoutmodes. . 79
IBCin<iiolt« l iglu> - non·~m<><l<! . 79
Installation a nd serv i ce
ce
rtificate . . . . . . 90
Repla ce ment parts . . . . 91
Dimensions and ratings. 1 02
Handling ce ramic fiber and fiber-
glaoo
mat erials. 106
NOTE S .............. 107
Pan number SS 0- 142·783/1012

GV90+ Series 2 OAS·FtRED WATER BOILER - Boiler Manual
Please read before proceeding
Hazard definitions
The following defined terms are used throughout this manual to
bringattention to r. heprestnce of hazards of va ri ous ri sk lt•ttlsor
to i mpo r tant i nf or mat i on conce rn ing the li fe of the pr od uct.
lnd icares pr t.Se n ce of hazards th ar w lll cause sevt- rt
perSona l injur-J'• dearh or substa ntial prope r ty
damage.
lnd icares pr t.Se n ce of hazardsthat can cause sevt- rt
perSonal i njur) '• dearh or substantial proper ty
damage.
!A CAUTION 1 lnd icarespresence of hazardsthat will or can cause
mi no r ptmna l inj ury or pr optrty damage.
NOTIC E
IAwARN IN &l
NOnCE
Jndicares speda l in srruct io ns on in sra ll at i on.
Opt-ration or ma intenance th ar are i mpo r tanr bur
no t related to ptrso nal inj ury or proptrty damage.
Installer- Read all instructions. i nd uding th is
man ual and all othe r in for mation shipped with th e
bo il er>before installin g. Perfonn steps in theorder
gi
.. · tn.
U ll er- Thi s manual isf or use only by a qualifi ed
he-at in g installer/service technician. Refe r to User's
Jn:f'onnation
Ma n ua J fo r your referen ce.
User -Ha\'t this bo il er serviced/inspected by a
qualified service technidan,at lea stannually.
faj lu re to comply wi th th e above could res ul t in
sevtrtpersonalinjur y, deathorsubstantia]proptrty
da.mage.
W~ i tt in the CP nu mbtr in the space provided on
the Installationcertificate on page 90 if notalready
shown.
\Vhen call ing or wr itingabout the boiler- Please
have theboil er modelnwnber from the bo iJ tr raring
label and the CP number from the boi le rjacket.
Consider pipingandinstallati on whendetermi ni ng
bo il er location.
Any claims fo r damage or shorrage in shipment
must be filed immedlatel y against the transportation
companyby theconsignee.
Commonwealth of Massachusetts
When the boi l-er is installed within the Commonwealth of
M..,.chu.setts,comply with <he following.
This produ ct must be insta ll ed by a licensed plumber or gas
fitter .
Ifantifreeze is used,a reduced pressure back-flow preventer
d.,;ce sha ll be uStd .
tf si dewa JI \.'tnt or ve nr/air is insra ll ed> see instructions on
page 34 .
Part n um ber 550-1+2-783/1012
~WARIM I Fa il ure to adhere ro the guidelines on thi.s
page can r esu ll in severe personal i nju r y,
Cleath or substantia]proptrtydamage.
When ..,,.,.;cing boiler-
To avoid electric shock, disconnecrelectr ica Jsupply
before performing maintenance.
To avoid severe burns, a ll ow boiler ro cool before
performing maintenance.
This bo il er contains ceramic t'ibtr and fibe r ~ l ass
materials. Refe r to the WARNING and instructions
on page 1 06.
Boiler operation-
Do not bloc.k flow of combustion or \ <entilation air
to boi l er .
Should ""erhNUng occur or g .. aupply 11111 to
tMit off, DO NOT tum offordisconnect electri cal
sup. P.Iy t ~ ci rculator. Instead> sh~r off thegassupply
at alocanon externaJto theapphanct.
Do not UM thla boilerHany ~h .. _.,under
woter. Immediately call a qil3lifi ed s ervice techni-
cian to inspect tht boi le r and to rtp l.act any va: rt of
the controlsystem andanygascontrol that hasbft.n
under wate r.
Combustionair-
DO NOT In sta ll combulllonairIntakewhwethere
It a rltk of combustion air contamln.Uon.
Carbonmonoxide detector-
Fo r OII'Cid Exhaustuni ts, acarbon mo n ox i de detec -
tor is requir ed in th e bo il er r oom . Thecarbonmon-
oxide dttecror must be wired on
th e same electri cal
circuit as the bo il er.
Fo r Direct V•nt units, a ca rbon monoxide dttecror
that i.s wirtdonthesameelect ri ca ld rcuir as theboiler
is stro nglyrecommended.
Boiler water-
Thoroughly flu sh the s ystem (without boiler con-
neo ted) to removeS<'dinlenl TbehbUI - ellic.ienc y heat
exd1anger can be damagedby build-uporcor ros ion
due tosedi mt nr.
Do not lL~t JH:trole um-based dea ni ng or staling
compoundsin boi
le r S)'Stem. Gaskets andseals in the
system
may bedamage<t. This can r esu lt in substantial
property damage.
LNk o ln boiler 0< piping ,.....t be repeiN<I otonce
to P<8Yenl moke-t~p woter. U se thlo boiler ONLY
In • ciOMd-toop system. Contin ual fre.sh make -u p
wat-er w ill rtduct bo il er l ife. M in eraJ bu il dup in heat
exchangersreducesheattransfer, ove rh eatsthemate-
ri als, an <I cause.s tanure.Addition of oxyge ncarriedin
bymake-
up water can cause intern al co rrosion.
Do not add cold w.ter to hot bolter.ThennaJshock
ca n cause heat exchanger to crac k..
Freezeprotection fluid• -
NEVER u.se automoti\·t orstandard glycolantifrtt:ze.
Use only freeu- pr o te c tl on fluids made for hydronic
systems. Fo ll ow aUguidelinesgi,· tn br. the antifreeze
manufucturer. Thoroughly
dean ana flush apy re-
placeme
nt boiler system that has used gl )'cO Ibefore
m sr.a ll ing th e n ew boi le r.
5

GV90+ Series 2 oAs·FIRED WATER BOILER - Boiler Manual
Prepare boiler location
Installat io ns must follow th ese codes:
Lo<a l, srat:t, provincial,national codes,J aws, regulations and ord in anc~.
National Fuel Gas Co de , ANS I Z223.1 -latest edition.
Standard for Controls and Safety Devices for Au tomatically Fired
Bo il ers, ANSf/ASME CSD-t, when r ~u i r M.
National Ele ctrical Code
ForCanadaonly: Bi49.i or Bl49.2 InstallationCode and CSA C22 .1
Canadian EJect r icaJ Code Pa rr 1andanylocal codes.
The GV90+ bo iJ t r gas manifold and con tro ls m~ safe lighting and other
perrormancecri te riawhenbo il erunderwenttestsspecifiedin ANS I Z21.13
-latest edirion.
1 MOneE 1 For th e Commonwealth of Massachusetts, read and fo ll ow
rhespecial instructionslocated on page34 of this manual.
Insta ll the bo i kr so controlS)'Stemcomponrnts ~ protected
from ti'lpplng or spraying water or ra k'l dur ingOptrntion.
Al lowin g. these compone nts to become wet cou ld cau~ a
bo iler faiJu rt, resulting in severe personal i nju r y, death or
substantial proprrtydamage.
H ig h altitude Installations
GV90+ bo il 6' <Mirols •utofililitAIIy toduttinput wit h ina~ing alritudt.
See Fi gu re 1 for estimated inp ut at altitude as a percentage of St:a level
i np ut. Multiply the bo iler sea level input b)•this ptrc~ntage to obrain the
est imated high aJtitude i nput . Note that the length of the •tenting systttn
wi ll also h ave a min or impacton input. Refer to the ve nt supplement l' ..,r
fur ther in fo rmation.
No mo dificati o ns to the boiler s hould be nece ssary for installatio ns up to
s.soo fee t above St:a level. Fo r higher e-levations . the air pressu re switdl
musr
be changed to aspttial high altitudeswitch. Refe rro thehighaltitude
kit instructions, page 10. Note that the gas \<a l ve outlet pressure mu~ be
checked (andadjus ted if necessary) fo ll ow in g insrructions onpage 63 .
N OTICE
M OnCE
DO NOT oldowall vtnt DIRECTEXHAUST APPUCAnONS
ar alr i rud~s abo\re s.soo feeL Si dewa JJ ventingis only allowed
for DIRECT VENT app lications ( ducted combust i on air ) nt
altitudes a1x we s.soo fee t
Ve nr length aJso affects bo il er input- the bo il er auromati-
ca Ji yderatesrocompensatefor pressurt &oss through the vcnL
See the d~rate values give n in Figure 109, page 103. Fo rhigh
alrirude
inst:a Uartons, m ul ri pl y ihe% in Figure 1 rimes tht'
\'ll ]ueshow-n in Figure 1 09 ro d~erm i ne input vs sealeveL
Service clearances
When possible. ins ra ll GV90+ bo ilers wir.h dea.rances at least as large lt.'i
shown in Figure2 fo rbest service access.
Flooring
The GV90+ boiler is • ppr ove d for installation on combustible fl ooring,
bur
mu.sr neverbeins ta ll ed on carpeting.
6
Do n ot ins rall bo il er on carpeting even if foundation i.-.
used. Fi r ~ can resul t, causing severe personaJ i nju r y, death
or subsran tiaJ propertydamage.
Figure 1 Estimaled GV90+ input at altitude
Altitude
% Sea leve l Input
( fee t )
1 000 97
2,000 93
3,000 90
4,000 87
5000 83
5,500 82
6,000 80
7,000 77
8,000 74
9.000 72
10,000 69
Figure 2 Serviceclearances(recommended)
TOP VI EW
-··
W"'l
~ 6'
i ml"
0
i%
- ~ """ ~
~
36'
,. .... >
...
lir
8GIIL>r
rront
:w
••
I
'
W•ll cr oo:nn.ctlo-1!
FRON TVIEW
-·
C~ l na
l
I
~ -
••
::1
3:
! j
36"
R. ,. , Ql
s·
rln
- ~-
hool
Fl .. ..-.
l•.an num ber 550-l-42-783/10 12

GV90+ Serie s 2 fi A !i -fll ~o w _".,. IIO l L-1!11 -BaU er M anua l
Prepare boiler location (continued)
Foundati . on
Providt a .sQiid b r:lck or <Q . ocmo foundation pad it llny oi' the fol l owing
is possible:
When the floor ca .n becoll)f flood~
Whto (hr: boiJI(-r mbuntin_g ak:il is n ot l. e're l.
When a high -profile condensaie pump is u sed, provide a foWldaiion
bigh c:-nOug h tl:\at lhr:GV90+c(mden,sat,t cOnnecti l )n is at least as hfgli
-as the t.Xmd( n sat~ pump inl t-r c(u i. ne<tio u.
Figure 3 Min im um fll<J!ldalion dimeosians (inches)
Boll or model w L H'
""""
G~ / GV90+4 11!;
301'
2
GV90+SI GV90 +6 16 371' 2
~
• lnCI'tllk heighl if nttded LU auo re
e;mdcmioll !rnp iltlil<U~ ilHilluv~ inlet -------= ~ ---~-- + - · ~ ::..,
vf condc"nsate puJnp. v/Jttn u&erd.
Residential garage Installation
Precautions
Take the fo ll ow i ng sptcial precautions when installing r. he builer ln u
residmtiaJ garage. If the bo iler is located in a residential garage)~ ANSI
Z223.1,parngraph 5.1. 9:
Mo un t the bo lltr a min i mum of 18 Inches above the floor of the
garage ro assutrt the burner and ignition devices will be no J~ thon
18 inc . bes abO\~e the fl oor.
Locate or protect the bolktr so it cann ot be damaged by a muving
\'fhi de.
Minimum clearances
I AW AHNING I
You can in.s mll GV%+ bo iJ ers in spaces s ma ll er thA H Fig-
ure 2. page 6 recommended servi ce dearances. but n ever
smaJ Je:r th an shown in Fi gu re 4.
I nstallat i ons wi th clearances less th an shown lP Fig-
ure 2, page 6 musr ha\'f air ope ni ngs si ud and l tKat.ed as
shown in Figure 4.
Alwa ys providearleastscrewdri\'frclearance to jackrtfront panel St."t't'\'f' s
for rt:mO\'al of fronr pane-l for inspection and minor sen·ice.
Iftheboilerc-annot be serv~ In place . pipe the boi l er with uruuus
and i so lati on valves so it can be sl id ou t of rhe space and krvic«< iu
an adjacent area.
The space has to be equ ipped with a door so boiler can be ue<:cs.'icd.
unpiped and ~ moved.
Part nu m ber 550-1+2 -783/1012
Figu re 4
Min imum ci~(J$ - whoo
clearancas me lliSs th an rocom •
mended $ervice clearances olFi g-
ure 2, page 6, inslali as shown below:
TOP VIEW
... 4_:..
m in
Fr ont
Wall
t
10"
min
~ f~ .
El<>iler
t op
Wal l
A ..Arta ad ja ct:n~ «> ac:-cos d<l(tl' mus ~ lko acct!1~ible.
and m\!S~ allow for ~(tval () ( l,heGV90,..boile.r
f ot" .se-rvict-.
iNo o tJ~r ... pplilnC'I:' or a. i.r mowr (~x hau s t l1 1ln,
etc .) n'my l,t m.JwHel;l in th~ samt fpacc.",
B ..Aca.~DOOR IY ilh fft'.AA nir upenin~tr.:
C !ProVide 1,2) Freshait ~ pccios< - ~odl Wfth al.
l~mst 15q. inch p er UM)U Btu'l1 or bolter input
~
f'
SI DE VIEW
C ol l lhg
6 1' mll ll' l -Accessdoor t ,.
+ m.,
co:::
1i
4. -
Bo11 ~ l ,r~
-i: ...
"
£ &i
dll
"""
6
11
l'I'W( l F
lo cn
NOllC E SPECIAL REQUIREMENTS
FOR AIR OPENINGS : Flif it;,tiill•ti<lill
~-lith dta tan ceo. lt.'.-t than rec ~: J"mm tndtd
&t:tlfic.e dt:tr'ances{Fig ure 2. pagt 6 ). b ul
no klu than shownIn Agure 4 - An
occess door must: be provided,fitted wlth
LWO iti.r ypw.io&S a5 shllWn io Fit.'l.trt' 4 ~
Each ltl)t-nirtg, mlJstba\ t: .i ft« n l' ea nu
l es~ t.lun J ~uttre inch pt r I OOtl Btuh
iurut uf tt,e- GV90+ boilc:r iu the spacr.
DO NOT apply lht air aptnlng alzH
given In Aguro 42, page 36 or FJg ..
ure 60, pa;. 50 .
7

GV90+ Series 2 oAs·FIRED WATER BOILER -Bo ll er ManuaJ
Prepare the boiler (continued)
Check orifice plate - replace if necessary
TheCOf'l'tltCtortflceplatemustbe used. Fa iJu rt to do so
will resuJt in severe persona]in jur y. death or substantial
propertydamage.The bolltrls shipped with a natural
gas ortflct plate. h MUST BE CONVERTED to uu
propane.
Natural gas:
For n atura l gas installations. Inspect the sUver gas/air ortflee plate
marking. It must be the same as the boiler size. If the orifice plate is
stamped with anothe r si u, obrain the co r rtct platefrom your who le-
saler.The bo il er si 7.t is sramprd where the .. X "' isshown in rhe plate
stamping. Figure6.
Propane:
For propane insral la ri on s, nplac• the sliver gas/air orttlc• plate
with the redlwhtte plate , perfo ll owing instructions. Ensure the r ~
white plate bo il er siu is co rrtct fo r the GV90+ bo il erbeing installed.
The bo il er siu isstampedwherethe
1'X
.. is shown in theplatestamp-
ing. Figure6.
Also fill o ut the propane label in the com-ersion kit andattac.b to the
lefrside of thejacker,abovethegasinletopening.asshown in Figure5,
Orifice plate installation, when required
AcctsS th e bo ttom of tilebl ow · er housi ng asshown in Figure5.
To inspect
th e plate on ly. read the marking on the plate edge. It
musr read rhesameas · th e bo il er Si 7.t and fuel , as fo ll ows:
Boltr model Natural
gas martdng Ptopane mar1dng
GV90+3 NG3SEC LP3SEC
GV90+4 NG4SEC LP4SEC
GV90+5 NG5SEC LPSSEC
GV90+6 NG6SEC LP6SEC
To r ep l ace r. he plate. usinga maooal scn wdrtver or nut Qotver . see.
Figur e6:
1. Loose n screws 1 and 2 two fu ll turns.
2. Remove screws 3 and 4.
3. PuiJ the gas/air oriffice plate forward to remove it .
4. Sl id e in th e n ew plate as shown in Figu re 6. T he nd side of a
propane plate nut go next to the bloww housing.
5. Rep lacescrews3 and 4.Tighten all fo ur screwssecurelyand uni-
formly. DO NOT overtighten. DO NOT exceed 40 inch -p ound$
torq u e.
6. lk nd down plate label rabatscore mark as shown in lower right
comerof Figure6. it
em 10.
jAwARtM I
8
DO NOI' use elect ri c or pnewnaticscrewdri\·ers to re-
move or tighten
r. hegas/air boss saews. Hand-tighren
onl y, usi ng manuaJ SCTtWd ri \·er.Shou ki rhe torqueexcted
4() inch-p ou nds. the th readed holes co ul d str ip ou t,
causing an inadequate seal ofthe orifice plate . Failure to
properlyseal theplate to thehousingcould resu lrina gas
leak.caus in gse\rereperson al injur y, death orsubstantial
property damage.
Figure 6 Check for c orr ect gas o r~i c e plate
A :R.emow j s.cktt. &oot
p an~l to aa:~$ thf'bot-
.m m ~ide-Qf t he bl ower
housing.
B Co. mp lcte1t,el'fopane
connrsion labelind
ud -
«1 Wit h th.e COP\ttn i Qn
kit. Insr.a.IJ labt. loo.j.:td:d
ld'tt ida , 11$ Mlawn.
~ t he f;Joil~ oo.lts ba ck,.
on theskid 8$ shown, !Jn til
yo u ~love chocked thr g;oi/mr
~ ri6ce plateand n!pl.aoe it if
11cce658t y.
Figure 6 Fo ll ow in sv uctJonsto c he ck 0< replace
gas or. ijice plate rx· = boiler size)
1-4 .!ia'twi-follow lt • itrt~t:Ubnt fot l ~lns and li r;htal.ins;
S C:a~a.il:' manifold
6 Fn,nl ~ ti on., bouamvi ew, campon nu dtull.tomiJkd
7 $Me $bcw.tttmu.tt po;lnt t (I'Wa rd -aif lltlt1h ttte- WARN lNG
llibtf fll.de lO r1At unl ~ WH'ITI:-d de fo r propane gM
8 PtopuleOtifictplate.RBDaoe6ideandWHIT.Eon th~
4tbi:r ( ttd skit n\11St ~ dw ~rhou..~
9 Natw-a:lg:uotifio:e plate . SIIYE!R
10 Orificepbteafterbendtngalong Kote mack - l.tbel 111
\liu"b lt w l ~ im.UJ IM
P3n num ber SSQ-142-7831 1 01'2

GV90 + Series 2 oAs·FIRED WATER BOILER - Boiler Manual
Prepare the boiler (continvedJ
In sta ll cond en sate tr ap
I. Btlo re plac ing the boiler in pos 'irton, install the condensate. tr ap
lint,shown in Fi gu re 7.Itemsshownare pr O\' ided wi rh the boiler.
Slop 1 Attach the flue draJnh ose (C) to the in-liue flue drain
nip ple (B) .
Step 2 Slide a scTtW driver or prnc iJ through the condensare
dra in n ipp le (G).
Slop3
Slop4
Step5
Slide r. heend of r. hescrewdri\'fr or ptncil in rothe open
end of t ibe flu edraJn b ose (C).
Feed the in-line flue drain (A) assembly into the flue con-
nection (D),guidingthe
flue drain hose th ro ugh th econ-
densate dra in nipple (G) with r. ht screwdriveror ptnciJ.
Press the in-line flu edraJn( A) into the flue connection
(D) and thro ugh the se al r ing until it reaches the srop .
Thentighten tlie flue connection b ose damp to secure .
The flue drain bose (C) sho uld now extend down past the
end of tilecondensate drain n ipp le (G).
Slide t he U-cl amp (F) over the co ndensate trap tee(E)
and i nt:o r. he two ho l es in the rai l. Atrach th e twonuts pro-
vided tc> the U- damp and righren rosec ure the condensate
trap tee ro ther ai L
Sl ide l'he ends of the condensate trap hose (H) on to the
con densa te drain n ipp le (G) and r. he condensate trap tee
(E).Secure thecondensate trap hoseat each end with tht>
hose damps (J}.
IA WARNNG I Choc:k
tho holght o1 th o condonsato trep , .. outlot,
Bef o re rotating the bo il er i nto pos ition, me asu~ lhf"'
distttnce from the con densate t~ ou d ~ ro the bottmn
of th .e bo iler mountingra ll s.When the boilerisplaceio
position, rhe co ndensate tee outlet musr be higher Lb an
the condensa te pump inler connection (wh en a con-
densate p ump is used). Increase the foundation hefghl
if nt<tSSary.
Part n um ber 550- 14-2 -783/1012
Figure7 Insta ll condens<~ l e trap
A lo-Outdnin
Fint.hed MMtnbty
B Au..e draln nfpplt
c Flu.t dni:nbose
0
'f1u.t c:anne:.don
E Co n.;Jcnsalf' tnq • let
F u~~ud oo L~ (oot,
•b -)
G Con den~itt dn.lri
nipPle
H Con denAuo lnlf' hcl.l;e
J H
~ · d.amp~
9

GV90+ Series 2 oAs·FIRED WATER BOILER - Bofler ManuaJ
Prepare the boiler (continued)
Install hi gh al ti tude air pressure switch
when requ i red (onl y above 5,500 feet)
1. For installations at altitu de mo re th an S.SOO feet abo\re sea level:
a. A special high a ltitude airpressure swirch i.s r ~u i r M.
b. The gas valve outler pressure seuing mu st bt checked, and
adjust~ ifnecessar y) per the instrucrions on page63.
" IA " w " AR = IING =~I Failure ro check gas va l ve oudet pr ess ur e and adjust, if
necessary> couJd result in St'\'ff't personal injur y, dearh
or substantial proptrty damage. Ca refu ll y follow the
gu idelin e$ gi ven in this manual
2. Obta in the GV90+ hi gh altitudekit from )'Ou r l oca lWeii- Mcta in
distributor. The hi gh altitude kir co ntains the high altitude air
pressureswitch.
3. See Figure 8 (sw itch shown with wi res removed}.
a. Remove the two (REO) contro l wires from the air pressure
swirch spade te:rmi nal s.
b. Remove r. he factory-installed ai r pressure switch (loosen rop
screw and remove bottom screw holdingswitch to jad:er in-
tt'r'iO r panel).
c. lnsraU r. he high alri r.ude air pressure switch in the same loca-
tion.
d. Cart fu ll )•replacethe hOStS on rhe new switch. with the rtd hose
on the hose ba rb cloStSt to theelectrical spade connecrors.as
$hown in F i g"~$. Th¢whi!¢ hQI¢g ~o n !h~ o!'h~rh~ba r \>,
e. Replace the two ( RED ) cont rol wires on r.he new pressurt:
swarch spadete:rmi naJ s.
Rotate the bo i ler I nto posit i on
!A CAUTIO NI Boilerisshipp<d on backside.lt must b< taken off skid
and rora ted inro co rrect position.
Afterinstallingcondensateline.inspecting(replacing if necessary) r. he
gas/alr orifice and Installing t he highallilude kit ( If required), m ove
the bo ll t'r' near its position.
Figu re 9 shows r.he boiler with r.he front and top panels r ep laced.
These pantls may bt left off if desir ed unr il rhe insrallarion h as bet- n
completed.
Bo iler i.s h eavy andcon ta in ssomesheetmetalpartswhich
may have sha rp edges. Wea r giO\'fS when h and ling and
rake pr ope r precautions when mO\'ing. Failure to do S6
will resuJt in St\'frt persona]in jur y. death or substanri al
property damage.
Refer to Figure 9forplacement sequence as fo ll ows:
1 W ear hNYY gk>ves -cartfu ll y roratt r.he boiler over onto its
base ra il legs.
2 Clip the shipping strapsecuringtheskid to the bo il erblockas-
sembly. Remove th~ skid and strap.
3 Attach the)ack tt rtar panelasshown using (4) II Ox ~»screws
pr O\<ided in theaccessory bag.
10
Figure8 Air pressuresw it ch moun~ n g
1 lntmtw poliJII!:I COl?
2 J~1 ld1 sid~ panel
3 Air pres- tuft' !M"i t cb
4 WHrTEb oilli-
5 ReD-
8
MoUnlin.l-i.::r"""
Figure9 Follow instruct ions toperloon the s te ps
sh ow n bgtow
P.anntunberSS0-142-7M/10 12