Part number 550-143-010/1021
60
GV90+
series
2
gas-fired water boiler – boiler manual
2. See Replacement parts,
Figure 97, page 91
of this manual
for Weil-McLain part numbers to obtain antifreeze through
a Weil-McLain distributor.
Use the correct amount of antifreeze
1. Determine the freezing temperature needed (to protect
against lowest likely temperature the system water will en-
counter).
2. Find the antifreeze concentration by volume needed for this
temperature from the antifreeze manufacturer’s data on the
antifreeze container.
3. Add up the volume (gallons) of all system piping and com-
ponents, including the expansion tank and boiler.
a. Boiler water content is listed in
b. Remember to include expansion tank water content.
4. Multiply this volume by the (percent) antifreeze needed to
find the number of gallons of antifreeze to add.
Fill and test water system
Fill system only after ensuring the water meets the requirements
of this manual.
Purge air from water system
1. Connect a hose to the purge valve (see purge/drain valves in
piping diagrams beginning with
. Route
hose to an area where water can drain and be seen.
2. Close the boiler or system isolation valve between the purge
valve and fill connection to the system.
3. Close zone isolation valves.
4. Open quick-fill valve on cold water make-up line.
5. Open purge valve.
6. One zone at a time, open the isolation valves. Allow water
to run through the zone, pushing out the air. Run until no
noticeable air flow is present. Close the zone isolation valves
and proceed with the next zone. Follow this procedure until
all zones are purged.
7. Close the quick-fill water valve and purge valve and remove
the hose. Open all isolation valves. Watch that system pressure
rises to correct cold-fill pressure.
8. After the system has operated for a while, eliminate any re-
sidual air by using the manual air vents located throughout
the system.
9. If purge valves are not installed in system, open manual air
vents in system one at a time, beginning with lowest floor.
Close vent when water squirts out. Repeat with remaining
vents.
10. Open automatic air vent (diaphragm-type or bladder-type
expansion tank systems only) one turn.
11. Starting on the 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 correct system pressure. Correct pressure will
vary with each application.
a. Typical cold water fill pressure for a residential system is
12 psi (when using a 30 PSIG boiler relief valve).
b. Pressure will rise when boiler is turned on and system wa-
ter temperature increases. Operating pressure must never
exceed 5 PSIG less than the boiler relief valve setting.
3. At initial fill and during boiler startup and testing, check
system thoroughly for any leaks. Repair all leaks before
proceeding further.
Eliminate all system leaks. Continual fresh make-
up water will reduce boiler life. Minerals can build
up in sections, reducing heat transfer, overheating
heat exchanger, and causing heat exchanger failure.
Check/verify water chemistry
1. The system may have residual substances that could affect
water chemistry.
2. After the system has been filled and leak tested, verify water
pH and chlorine concentrations are acceptable.
3. Verify antifreeze concentration, when used.
Check inhibitor concentration
annually
1. Test the pH of a sample of system water at least annually. The
pH of the water mixture must be between 7.0 and 8.5. (Or
use the Sentinel inhibitor test kit to check concentration.)
2. If pH is outside this range (or inhibitor test kit indicates low
level), the inhibitor level may not be sufficient to prevent
corrosion.
3. Test antifreeze concentration.
Test antifreeze concentration at least annually. If
concentration is low, add antifreeze or drain system
and refill with correct mixture.
4. Follow instructions on antifreeze container to determine the
amount of antifreeze needed.
DO NOT
exceed 50% by volume
concentration of antifreeze.
5. Check inhibitor level after adjustments are made.
Verify gas/air orifice plate
The proper orifice plate must be used
. Failure
to do so will cause severe personal injury, death or
substantial property damage.
1. Remove the jacket front panel.
2. Read the boiler size written on the gas/air orifice label tab,
verifying the correct size. See
for details.
3. The orifice plate must be plain aluminum for natural gas.
For propane gas, the exposed tab of the plate should be red.
4. Replace the orifice plate if necessary, following the guidelines
on
Start-up
(continued)
