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Part number 550-143-010/1021

GV90+

series

gas-fired water boiler – boiler manual

Troubleshooting

(continued)

INDICATOR LIGHT

CONDITION

POWER

Flashes once per second

120 VAC connection to boiler

reversed or there is insufficient

earth ground.

Flash code 2*

Internal fault, microprocessor or

memory.

Flash code 3*

LWCO circuit.

Flash code 4*

Unused.

Flash code 5*

Internal fault, water thermistors

disagree.

Flash code 6*

Flashes once per second

Internal fault, gas valve circuit.

* Flash code pattern: POWER LED flashes 2, 3, etc. times rapidly

followed by 2 seconds off, then repeats.

Control indicator lights —

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.

OWER light flashing alone

• Usually indicates reversed polarity of 120 VAC power wires.

POWER and TSTAT/CIRC lights flashing

• Usually indicates stray voltage on external thermostat circuit wires or

return water temperature entering boiler sections has not reached 130°F

within 30 minutes.

POWER and PRESS SWITCH lights flashing

• Usually indicates pressure switch is closed when it should not be, or

pressure switch failed to close within 5 minutes of blower starting.

POWER and FLAME lights flashing

• Flame sensed without a call for heat or out of sequence during ignition trial.
• Usually indicates control has had three unsuccessful ignition attempts

or sensed flame when it shouldn’t be there. Boiler may not be properly

grounded.

FLAME lights flashing

• Flame loss, or flame not sensed during trial for ignition. Boiler may not

be properly grounded.

Solid LWCO light

• Low water condition occurred.

LWCO light flashing alone

• Three (3) rapid pulses indicates LWCO requires maintenance.

IBC indicator lights — non-lockout modes

TSTAT/CIRC light flashing alone

(Freeze Protection)

• Usually indicates return water temperature sensor detects water at boiler

return pipe less than 40°F. Both internal circulators will run continuously,

even with no call for heat, until temperature rises.

LIMIT light flashing alone

• Usually indicates an open or shorted return water or supply tempera-

ture/LWCO sensor.

Troubleshooting the IBC

• See

Figure 93, page 80

for location of harness plug receptacles and plugs

on the IBC.

Integrated Boiler Control (IBC)

Make sure

ground wiring

is installed per wiring

diagram. Good grounding is extremely important for

proper operation.

Solder or water

splatter between plugs

and circuit board can cause improper

operation of IBC. Place a shield over the

boiler internal controls and components

during installation. Failure to comply

could result in severe personal injury,

death or substantial property damage.

IBC indicator lights — lockout

modes

• See Charts 1 through 8 in this section for detailed

trouble-shooting procedures.

• To reset control after a lockout, turn off power at

the 120VAC service switch or turn down all ther-

mostats. Wait 45 seconds. Then restore power and

call for heat.

• After an over-temperature lockout (POWER and

LIMIT lights flashing), the control will only reset

after interruption of 120VAC for 45 seconds. (And

temperature at return water temperature sensor

must be below 240°F.)

Figure 92

GV90+ Integrated Boiler Control (IBC)

Содержание GV90+

Страница 1: ...nstructions 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 dam...

Страница 2: ...if the temperature in the boiler goes above its setting The circulator will continue to run as long as there is a call for heat The low water cutoff LWCO sensor will shut off the boiler when the wate...

Страница 3: ...Part number 550 143 010 1021 3 GV90 series 2 gas fired water boiler boiler manual GV90 Series 2 Water Boiler...

Страница 4: ...oubleshooting 76 Installation and service certificate 90 Replacement parts 91 Dimensions and ratings 102 Handling ceramic fiber and fiberglass materials 106 The following defined terms are used throug...

Страница 5: ...could resultinfrozenplumbing andwater damage in a matter of hours For your protection take preventative actions such as having a security system installed that operates during power outages senses lo...

Страница 6: ...ee Figure 1 for estimated input at altitude as a percentage of sea level input Multiply the boiler sea level input by this percentage to obtain the estimated high altitude input Note that the length o...

Страница 7: ...GV90 3 GV90 4 16 30 2 GV90 5 GV90 6 16 37 2 Increase height if needed to ensure condensate trap outlet is above inlet of condensate pump when used Residential garage installation Precautions Take the...

Страница 8: ...For propane installations replace the silver gas air orifice plate with the red white plate per following instructions Ensure the red white plate boiler size is correct for the GV90 boiler being inst...

Страница 9: ...e instal lation and operating conditions Prepare the boiler continued Figure 7 Install condensate trap Install condensate trap Before placing the boiler in position install the condensate trap shown i...

Страница 10: ...move bottom screw holding switch to jacket interior panel c Install the high altitude air pressure switch in the same location d Carefully replace the hoses on the new switch with the red hose on the...

Страница 11: ...r during the fill Valve and nipple are not included with boiler Step 6 Install a pipe plug in the relief valve opening top of the rear boiler section as shown Plug is not included with boiler Fill and...

Страница 12: ...e personal injury death or substantial property damage General piping information Minimum pipe size for boiler loop piping Figure 11 Provide boiler loop piping no smaller than listed below based on 20...

Страница 13: ...g Undersized expansion tanks cause system water to be lost from the relief valve and makeup water to be added through the fill valve Eventual section failure can result Always locate the cold water fi...

Страница 14: ...d piping Legend 1 Relief valve discharge piping see page 12 2 Isolation valves 3 Fill valve 4 Diaphragm type expansion tank always locate as shown in the suggested piping drawings in this manual 5 Air...

Страница 15: ...diators or convectors DO NOT apply for radiant heating fan coil units or commercial installations Simplified pipe circulator selection 1 Install the boiler and piping using the recommended piping layo...

Страница 16: ...ely use a zone valve zone controller Do not use R C connections for zone valve DO NOT connect directly from 3 wire zone valves to the T T terminals on the boiler When using 3 wire zone valves install...

Страница 17: ...ees systems Theapplica tion information on this page is based on two pipebaseboardsystems To check whether the internal circulator can provide sufficient flow to a one pipe diverter tee system use the...

Страница 18: ...e removed for use a zoning circulator Provide a circulator for each zone when circulator zoning and pipe the system as in Figure 21 Balancing when required Substitute a memory stop valve for one of th...

Страница 19: ...systems contact Weil McLain The system circulator must be supplied by the in staller Adjust balancing valves Use valves 17 and 18 to mix boiler supply water with system return water reducing supply wa...

Страница 20: ...er temperature This is required to protect the radiant system from excessive temperature Zone valve zoning The suggested piping uses a separate circulator for system circulation to provide the higher...

Страница 21: ...can be adjusted to provide a return water temperature of at least 60 F Any setting higher than 60 F will also be acceptable Zone valve zoning The suggested piping uses a separate circulator for syste...

Страница 22: ...s in each zone to use the memory stop valve for balancing flow as well as isolation Zoning with zone valves Provide a separate 24 volt transformer to power the zone valves Size the transformer to hand...

Страница 23: ...oundation if boiler room floor is uneven or if there is a danger of flooding Size foundation to allow for clearance and spacing di mensions shown in the illustrations at right 4 Chalk line boiler loca...

Страница 24: ...nect from Easy Fit manifold branches to boiler supply and return connections using copper or steel pipe sized for the required flow rate 5 Provide a flow check valve in the supply piping of each boile...

Страница 25: ...t and size per page 24 6 Primary circulator 7 Expansion tank diaphragm type 8 System air eliminator 9 System automatic air vent 10 Pressure reducing valve 11 Check valve or backflow preventer as requi...

Страница 26: ...age 25 for typical com ponents 17 3 way diverting valve operated by DHW aquastat valve end switch connects across boiler thermostat terminals 18 System supply 19 System return 20 Boiler relief valve a...

Страница 27: ...return piping using a common circulator 22 Boiler water inlet 23 Boiler water outlet 24 DHW boiler side circulators 25 DHW boiler side return Easy Fit Manifold 26 DHW boiler side supply Easy Fit Manif...

Страница 28: ...facturer for heat ex changer shell side and tube side piping and circulator requirements Tube side flow and temperatures must meet heating system requirements 2 Contact heat exchanger manufacturer for...

Страница 29: ...iler CANNOT use the ex isting common vent The GV90 boiler requires its own vent and air piping as specified in this manual This may cause a problem for the appliances that remain on the old common ven...

Страница 30: ...structions in this manual see page 49 for air opening instructions and all applicable codes to provide required air openings DO NOT sidewall vent DIRECT EXHAUST APPLICATIONS at altitudes above 5 500 f...

Страница 31: ...be routed and terminated individually as described in this manual Flue gas leakage and boiler component damage can occur Failure to comply could result in severe personal injury death or substantial p...

Страница 32: ...ngth feet 3 100 100 100 100 100 100 100 4 100 100 100 100 100 100 100 5 100 100 100 100 100 100 100 6 100 100 100 100 100 100 100 Equivalent feet for elbows deduct from maximum equivalent length of pi...

Страница 33: ...nting Weil McLain bird screens purchase separately Bird screens Vent screen 3 W M part number 383 500 105 Note 1 DO NOT use DWV CPVC or ABS when using concentric vent termination Use ONLY PVC schedule...

Страница 34: ...cal gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage insta...

Страница 35: ...d or the Natural Gas and Propane Installation Code CAN CSA B149 1 The vent termination clearances below are for U S A for Canadian vent termination clearances please refer to the requirements of CSA B...

Страница 36: ...each at least 1 square inch per 3 000 Btuh of all other appliances in the room TWO openings each at least 1 square inch per 2 000 Btuh of all other appliances in the room OR ONE opening each at least...

Страница 37: ...be mani folded as shown in Figure 37 page 31 Figure 43 INSTALLATION W M sidewall vent air plate Step 1 Read and follow all instructions in this manual DO NOT proceed with vent air installation until...

Страница 38: ...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 e Cut holes in the wall as sho...

Страница 39: ...e manifolded as shown in Figure 37 page 31 Figure 47 INSTALLATION SEQUENCE Separate pipes sidewall Step 1 Read and follow all instructions in this manual DO NOT proceed with vent air installation unti...

Страница 40: ...the air termination elbow by inserting bird screens See Figure 47 page 39 Bird screens must be purchased separately See the parts list at the end of this manual for part numbers 2 When completed the a...

Страница 41: ...t within 6 inches of any upturn in the piping DIRECT VENT Sidewall with 3 concentric Allowable vent air pipe materials lengths 1 The 3 concentric termination kit must be pur chased separately Use only...

Страница 42: ...termination mount and secure the concentric termination as shown in Figure 52 The vent and air piping must be securely supported and must not rest its weight on the boiler fittings Failure to properly...

Страница 43: ...eter 2 Vent pipe penetration a Cut a hole for the vent pipe For either combus tible or noncombustible construction size the vent pipe hole at least 0 4 larger than the vent pipe diameter 4 hole for 3...

Страница 44: ...ual for part numbers 2 The air piping must terminate in a down turned 180 degree re turn bend as shown in Figure 53 page 43 Locate the air inlet pipe no further than 12 inches from the center of the v...

Страница 45: ...regard to spacing from adjacent boiler vents Prepare roof penetrations 1 Roof penetration hole a Cut a 5 inch diameter hole to clear the 4 inch termination outside diameter b Insert a galvanized metal...

Страница 46: ...her protection over the end of the exposed assembly to prevent debris from entering the pipes If the air passages become blocked the boiler will not operate Once the rain cap has been cemented to the...

Страница 47: ...f penetration to prevent debris from blocking the air passages 4 Use the following procedures to prepare termina tion components and cement together 5 Deburr inside and outside of pipe ends 6 Chamfer...

Страница 48: ...iler vent and air connections AL29 4C vent pipe If using AL29 4C stainless vent pipe you must install an AL29 4C stainless vent starter at the boiler vent connection andattheterminationifusingtheWeil...

Страница 49: ...will not start if this contact is open and will shut down should it open during operation Combustion air provision The GV90 boiler can use inside air if no contaminants are pres ent in the boiler spac...

Страница 50: ...e room TWO openings each at least 1 square inch per 4 000 Btuh of all appliances in the room OR ONE opening each at least 1 square inch per 3 000 Btuh of all appliances in the room TWO openings each a...

Страница 51: ...tions in this manual DO NOT proceed with vent installation until you have read page 29 through page 35 page 49 and page 50 Step 2 Install the boiler in a location that allows proper routing of vent pi...

Страница 52: ...the vent pipe hole as shown in Figure 62 2 Followalllocalcodesforisolationofventpipewhen passing through floors or walls Termination and fittings 1 If using a coupling or elbow for the termina tion pr...

Страница 53: ...and air pipe Wheretheventpenetratestheroof thean nular space around the penetration must be permanently sealed using approved materials to prevent entry of combustion products into the building Figure...

Страница 54: ...h or substantial property damage Close manual main shutoff valve during any pressure testing at less than 14 w c Disconnect boiler and gas valve from gas supply piping during any pressure testing grea...

Страница 55: ...s on inside walls away from influences of drafts hot or cold water pipes lighting fixtures television sun rays or fireplaces Follow instructions with thermostat If it has a heat anticipator set heat a...

Страница 56: ...rculators requires a relay for each circulator When using three wire zone valves take care to avoid mis wiring This can impose an additional 24 volts across the boiler control circuitry The IBC will s...

Страница 57: ...Part number 550 143 010 1021 57 GV90 series 2 gas fired water boiler boiler manual Wiring continued Figure 68 Ladder wiring diagram...

Страница 58: ...Part number 550 143 010 1021 58 GV90 series 2 gas fired water boiler boiler manual Figure 69 Schematic wiring diagram Wiring continued...

Страница 59: ...to directly heat swimming pool or spa water 3 Do not fill boiler or operate with water containing chlorine in excess of 200 ppm Antifreeze 1 Use only antifreeze listed by Weil McLain as suitable for...

Страница 60: ...e lowest floor open air vents one at a time until water squirts out 12 Repeat with remaining vents Pressurize system 1 Close manual and automatic air vents and boiler drain valve 2 Fill system to corr...

Страница 61: ...thermostat zone valve and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires 3 There should NEVER be a voltage reading 4 If a voltage does occur unde...

Страница 62: ...X adjustment position should be used to maximize energy savings Turning the knob counterclockwise decreases the delay time and should only be used in the event that the heated space becomes uncomforta...

Страница 63: ...gas valve body gas valve must be replaced Fluid in valve will cause it to malfunction possibly resulting in severe personal injury death or substantial property damage 6 Disconnect tube from hose bar...

Страница 64: ...l display read ing is above boiler water temperature and ignition sequence should resume Test additional field installed controls If boiler has an additional low water cutoff additional high limit or...

Страница 65: ...ntenance person Return instructions to envelope and give to owner Start up continued This boiler is equipped with a control system that automatically adjusts a time delay period to turn on the boiler...

Страница 66: ...ES 4 sec 6 Limit cycle Limit circuit open Gas valve closed Blower off after postpurge YES 30 sec 7 Flame outage Flame out YES 8 Thermostat satisfied Circulator off Blower postpurge NO 30 sec 9 Low wat...

Страница 67: ...Part number 550 143 010 1021 67 GV90 series 2 gas fired water boiler boiler manual Figure 76 Operating instructions Start up continued...

Страница 68: ...pect the water system page 69 Check water system chemistry page 69 Clean and refill condensate trap page 69 Inspect expansion tank page 70 Inspect air openings page 70 Inspect vent system and air pipi...

Страница 69: ...indication of a leak Inspect the water system 1 Verify all system components are correctly installed and operational 2 Check the cold fill pressure for the system Verify it is correct usually around 1...

Страница 70: ...ufficient expansion If tank size is large enough remove tank from sys tem and check charge pressure usually 12 PSIG for residential applications If tank won t hold pressure membrane has been damaged R...

Страница 71: ...cycle off Return dial to original setting 2 Inspect and test additional limit controls or low water cut offs installed on system Follow the device manufacturer s instructions Inspect gauges 1 Boilerp...

Страница 72: ...ays are clear Certain naturally occurring mineral deposits may adhere to the valve rendering it inoperative When manually operating the lever water will discharge and precautions must be taken to avoi...

Страница 73: ...as tubing from gas valve outlet by removing the four 4 screws securing the outlet fitting to the valve Save the o ring in the fitting c Remove gas valve and bracket d Hose from gas valve to gas air ma...

Страница 74: ...sconnect the vent pipe from the recuperator 1 The vent pipe must be disconnected at the in line flue drain see Figure 7 page 9 2 If the vent piping can be moved enough loosen the flue pipe clamp on th...

Страница 75: ...ns to the upper and lower recuperator flanges 5 Re insert the in line drain fitting into the recuperator vent adapter Tighten the clamp to secure in place 6 Re connect the plug in connector on the the...

Страница 76: ...nd securely plugged in and are not damaged Checking the air pressure switch Do not use manometer as shown in Figure 84 to test gas valve outlet pressure Where instructed in this manual to check gas va...

Страница 77: ...ructions in this manual carefully if testing gas valve outlet pressure Failure to comply can result in severe personal injury or death The gas valve outlet is bolted to the gas line adapter and sealed...

Страница 78: ...nt insert the sensor in water at that tem perature Use an ohmmeter to read resistance value between thermistor and thermistor common See Figure 93 page 80 for sensor plug details g If the measured val...

Страница 79: ...be properly grounded FLAME lights flashing Flame loss or flame not sensed during trial for ignition Boiler may not be properly grounded Solid LWCO light Low water condition occurred LWCO light flashin...

Страница 80: ...art number 550 143 010 1021 80 GV90 series 2 gas fired water boiler boiler manual Figure 93 Integrated Boiler Control IBC harness plug receptacle and indicator light locations Troubleshooting continue...

Страница 81: ...circulator size Frequent release of water through relief valve Expansion tank sized too small Call qualified service technician to check expansion tank operation and size Flooded expansion tank Call...

Страница 82: ...n 7 0 to 8 5 Insufficient water flow through boiler Check all valves to and from boiler Return to proper setting Confirm circulator size Metal flakes found in vent outlet or recuperator flue way corro...

Страница 83: ...are good Remove 120VAC IN plug Figure 93 page 80 Item 1 on Integrated Boiler Control IBC Using voltmeter check across top and bottom pins of 120VAC IN receptacle Does voltmeter indicate 120VAC No Yes...

Страница 84: ...the wires There should NEVER be a voltage reading If a voltage does occur under any condition check and correct the external wiring This is a common problem when using 3 wire zone valves Once the exte...

Страница 85: ...76 Replace if necessary Retest Clear passages and recycle boiler Recheck boiler operation Properly position blower wheel on blower motor shaft and tighten set screw Or replace blower housing assembly...

Страница 86: ...for tight wiring connections on gas valve and IBC Repair replace as necessary Recycle boiler by thermostat or service switch holding power off for at least 45 seconds Thermostat should call for heat a...

Страница 87: ...sequence of operation Figure 75 page 66 Is return water temperature sensor clamped securely to the return pipe in the boiler No Yes Remove CIRCULATORS plug Figure 93 page 80 Item 4 from plug receptac...

Страница 88: ...operation Figure 75 page 66 This is NOT a lockout mode The Integrated Boiler Control IBC should only be signaling that the water temperature sensor is either shorted or there is an open circuit across...

Страница 89: ...block to cool to room temperature Are block switch contacts closed No Yes Check across thermal switch leads with continuity checker Is circuit closed No Yes Check across limit switch contacts with con...

Страница 90: ...th owner maintenance person CHART 8 Troubleshooting LWCO and POWER light Solid and or LCO shown on display Electrical shock hazard Wherever you see TURN OFF POWER follow the instructions Failure to fo...

Страница 91: ...t All 560 907 723 Adapter 3 inch AL29 4C Vent Starter Saf T Vent All 560 907 724 Adapter 3 inch AL29 4C Vent Starter CORR GUARD All Contact Weil McLain Chemicals Antifreeze aluminum safe Sentinel X500...

Страница 92: ...uds 13 nuts 13 All 382 200 713 3 Intermediate section also required Section replacement kit All 312 200 110 4 Back section also required Section replacement kit All 312 200 130 Not shown Section repla...

Страница 93: ...Part number 550 143 010 1021 93 GV90 series 2 gas fired water boiler boiler manual Figure 98 Section assembly Replacement parts continued...

Страница 94: ...200 753 382 200 754 382 200 755 4 Jacket panel left side rear 3 4 5 6 382 200 762 382 200 763 5 Jacket panel right side 3 4 5 6 382 200 760 382 200 761 6 Jacket panel rear All 382 200 756 7 Jacket br...

Страница 95: ...Part number 550 143 010 1021 95 GV90 series 2 gas fired water boiler boiler manual Figure 100 Jacket assembly Replacement parts continued...

Страница 96: ...6 510 811 927 510 811 928 510 811 929 Orifice plate natural gas 3 4 5 6 510 811 934 510 811 935 510 811 936 510 811 937 7 Gas air manifold assembly includes gas air manifold gas tubing washers screws...

Страница 97: ...Part number 550 143 010 1021 97 GV90 series 2 gas fired water boiler boiler manual Figure 102 Blower assembly Replacement parts continued...

Страница 98: ...diamond gasket 382 200 721 6 Square cut seal gaskets casting 2 31 572 800 011 7 Diamond flange gasket 590 317 535 8 Supply manifold kit includes water manifold circulator gasket Taco 110 339 1 square...

Страница 99: ...Part number 550 143 010 1021 99 GV90 series 2 gas fired water boiler boiler manual Figure 104 Trim assembly Replacement parts continued...

Страница 100: ...578 4 Air pressure switch See Figure 101 page 96 item 3 not shown Wiring harness IBC to hot surface ignitor 591 391 819 not shown Wiring harness IBC to system and bypass circulator 591 391 824 not sh...

Страница 101: ...Part number 550 143 010 1021 101 GV90 series 2 gas fired water boiler boiler manual Figure 106 Interior panel Replacement parts continued...

Страница 102: ...scription 1 1 NPT Supply 2 1 NPT Return 3 Combination pressure temperature gauge 2 short shank 4 NPT Relief valve outlet 5 Plug dome 2 black 6 Junction box 7 Inlet air fitting 3 PVC 8 Flue outlet 3 PV...

Страница 103: ...UE are certified by AHRI AFUE is also know as Annual Fuel Utilization Efficiency or Seasonal Efficiency 2 Net AHRI ratings are based on net installed radiation of sufficient quantity for the requireme...

Страница 104: ...7 280 175 5 525 485 14 5 420 263 5 700 650 19 4 565 350 5 875 805 24 700 438 6 420 390 11 7 336 210 6 630 582 17 4 504 315 6 840 780 23 3 678 420 6 1050 966 28 9 840 525 7 490 455 13 6 392 245 7 735...

Страница 105: ...te 1 GPM 20 F rise GPM 40 F rise GV90 3 6 5 3 3 3 GV90 4 9 7 4 9 3 GV90 5 13 0 6 5 3 GV90 6 16 1 8 1 3 Note 1 All GV90 installations require a separate vent pipe and termination for each boiler Vent p...

Страница 106: ...r lining or base insulation from the boiler and place it in a plastic bag for disposal Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated...

Страница 107: ...Part number 550 143 010 1021 107 GV90 series 2 gas fired water boiler boiler manual NOTES...

Страница 108: ...Part number 550 143 010 1021 GV90 series 2 gas fired water boiler boiler manual...

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