Weil-McLain QV90+3, OV90+4, QV90+5, OV90+6 Installation And Start-up Manual

®

Series 2

Gas-Fired W ater Boilers

Boiler Manual

• Installation

• Startup

• Maintenance

• Parts

This manual must only be used by a qualified h eating installer/service technician. BEFORE ins talling, read

all instructions in this manual and all other information shipped with the boiler. Perf orm 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 boiler control

The

integrated

pressure switdl, i

to operate
for heat, the I

The JBC runs the biO'\\•

lets it warm up.

Aft

er

igniter warm· up, the I

flam

e.

The flam

fu

ll

cyde again.

hen

the room thermostat

W

wa

i.ts (or the

The

IBC indicator ligh.ts show nonnal sequence wh

problem occurs, the JBC
reason for the proble

While attempting to satisfy the heat demand,

temperature changes via the temperature sensors a

availab

le hot water w.

is needed, the sequence

heat

above is bypassed.

boiler

control (I BC) responds to signals from the room thermostat,

:n

let water sensor, boiler

the

circulators,

BC

star

ts

the

er

e

must

come

next

beat

call.

m..

tll

satisfy the demand, only running

wa

.ter temperature sensor and boiler limit circuit

gas

valve,

igniter and bl

sys

tem circulator and blower.

to

purge the boiler

DC

opens the

on

within 4 wconds

is

satisfied. the IBC turns off the boiler components

flashes

combinations

conti:nues..

gas

When

ower.

flue

passages, then turns on the igniter

vah-e,

or

of

lights which indica

the

control module m

DHW

2 Transformer

The

control transformer

reduces line

vottage

to

24

volts for the

3 Blower

The

blower pulls

m

ixturt into

4 Recuperator

The recupenttor

trading

additional beat &omthefluega

entering the boiler.

before

5 Water temperatu re sensor

The

wat~r

off

rhe

gas

circulator

6 System

The system circulator circulates water through the external

ra.te

ofthecirculator

entering t

7 Bypa

..

The

IBC

colder return "'a ter from the S)'Stem

th

e cast iron heat exchanger.

Whe

n

the

culatorand

it enters the cast iron sections, By balancing these

before

agai:n.st

condensation

Pump

mU$t re

i:n ai:

r and mixes

lhe

burner for coml

is

a stainless steel beat exchang

t~mptralur~

valv~

if

the

wlll conrinue to

it

with gas

xu:tio

n in

ws,

sensor

provides a signal

temprratur~

run

in the boiler goes

as long as there is a call for heat.)

circulator

i:s

he boil

er

.se<tion$.

controlled

by

Pump m

the

u.<

IBC,

n rema

circulator

operates the bypass circulator to

as needed

water

returning to the boiler

sy

stem circulator

in

the

main on boiler-

flow

cas

t iron heat exchanger e\'en if return

rates

do

Is

to

not rem

&om

side-

the-

er

that increases boaer e

Return waterpasws through the recuperator

depending on the temperatu

in

on

mi.x

hot water

to

prevent condensation

below IW F. the I
rai

se

the

return

m-e.

When a room thermostat caUs

rurns the igniter off,

the me will shut

en the lights are

nd

determines wheth

the

ci:

(if

used)

caJJs for heat. sequen

gas

th

e gas

valve.

and

down

on

steady. When a

te

the most

onitors

er

rculator. If additional

valve

and limit

The bla\\'et

boiler chamber.

fficiency

to

the

conrrol

(S)

boiler -

fro

BC

water temperature

flow

modu

abo~

its setring. (The

'Stem)

piping, The

re

do

not

remove.

m t

he

boil

er

of

regulate$

rate

the

s.

the IBC can protect

water

Is

flue gas

as low as

air

and

checks for

and

try

the

and

bkel

the

boiler

or

not t

he

ce

ci:rcuit.

forces

this

by ex·

le

to

turn

flow

of

the water

outlet with

es

bypass

ci:

up

to l40'"

6Cr

in

r·

f.

LEGEN

a

b R

c Combustion

y

d

D

Supply to

etu

3"'

FJ

ue outlet -3"'

rn from

P

VC

system>

connecti

1"'

system,

air

lnlet fit

on

PVC

NPT

I" NPT

ting -

conntc·

tion

e Gas

vaJve

regulated

- negati

gas

control

ve

pr~ss

urt

I Pressure/temperature gauge

g

FJueway

inspection port

CO\'tr

h Stnsor hose trap

Manual air

Relief

k Thermal

device

te:mptrature exceeds irs

m Condtnsate trap line

loose

n Condensate drain con

W'

PVC

F

vtnt

vaJ\ ·t

fuse-

a one·time fuse

that shuts boiler off

-sh

with boiler,

field

nection-

female

if

flue

strpo

int

ipped

installed

8

Air

pre

..

ure switch

The

ai:r

pressure switch signals

the blower.

the

IBC.te U

ing the control whether air is moving through

9 Return water temperature sensor

The

water tempera t

sectfons. The sensor sends this Information to the

to

adjust the cirrulator

exchanger.

UI'e

sensor monitors

fl

O\\'

rates

the

temperatu

to

provide at least 140'"

2

IBC

re

of

. The I

the water

P water

entering

BC

determines how m

to

the

boiler

the cast iron beat

uch

Thi

s boile r uses a negarive·

tgulattd

r
pressure

column

00

ha

n facto ry

t

gas valve, ser for

approximately -0.

.

NOT

set rhe

sett

Pan

outle

ing.

number 55

prtssurt
an outl

20"'

t

pr~ssurt

higher

0-

142-783/1012

-

et

water

GV90+

Series

2 GAS·FIRED WATER BOILER -

Boiler

Manual

GV90+

Series

2 Water Boiler

Part

num

ber 550-

14-2

-783/10 12

3

GV90+

Series

2

oAs·FIRED

Contents

How

it

works

.....

GV90

+ Water Boiler .

Pie

aM read belore

Pr

epa

re boilerlocat

Installations m

High altitude i:nstallatfons
Residential garage installation

Check orifice plate - replace

Install condensate uap. . .
Install h

required
Rotate t
Perform hydrostatic pressure

In

sta

ll water piping

General

Install reliefvah-e

Exp

ansion tank

Sys

tem water piping m

Orculators

Simplified pipe/cirrulator selection
Baseboard system piping - ORCULATOR

'ZOning

Baseboard system piping -

'ZOning

Radiator system piping

Single·

Ad;wt

Multi·

wne

Piping snow melt systems

snow

melt/space heating

Water

chiller systems . . . . . . . . . . .

u.<

igh

altitude

{onJy above

he

boiler into position

pipi:

ng informat

•..............

.................

(pri:m

arylseco

(d

irect connection)

wne

radiant h

b

alanci

ng

radiant heatiog system . . . .

Multiple boil er installat

Placing

mul

tiple

Conuolling multiple CV90+ boilers . . .

Piping multiple CV90+ boil

Multiple boil er water

Easy·Fit•

piping installation . . . . . . .

Ventin g & air-

When removing a boiler from an existing
common

Existing vent
Provi
Vent and
DIRECfVENTinstallations
DIRECT

Combust

Ma
RECT

Air manifold sizing . . . . . . . . . . . . 3 1

Commo

in

sta

ven

t system . . . . . . . . . . .

de

nifolded combustion

llati

tes

combustion air:

air termination options
EXHAUST

io

n air contamination: . . . . . 30

VENT multiple

nwe

alth of Mlls

ons

. . . . . .

Vent termination req uiremen

DIRECT VENT- Boiler room air

ope

nings . . . . . . . .

DIRECT VENT-

ve

ntfair plate. . . . . .

DIRECT VENT­r

ate pipe

s. . . . . . . .

.

p~eding

ion

n

fonow

these codes:

..........

air press

S.SSO

........

ion

.............

eth

ods

ncf

ary) .......

..........

eati:

ng

vah<S

, , , , , , , , , , 19

or

;Systems.

boi~s

. . . . . . . . . .

piping

genKal ......

t procedure

..........

installations

air

boib

inslallations

Sidewa

Sidewa

...

.......

...

.......

if

necessary. 8

.........

ure switch wh

feet)

......

......

t

est

.....

........

.......

...

ZO

NE VAL

........

or

heat

pum

combinati

ions

ers.

on

. . . . 2 1

....

. . . . .

•...

........

.....

.......

.....

option

(or

Dl

. . . 3 1

saohusetts

......

ts

..

......

ll

with W-M

......

ll

with oepa·

......

VE

WATER

DIRECT VENT

.2

concentric .............

.3

DIRECT VENT

5

rate pi

pes

..............

BOILER

- Sidewa

- Vertical with

6

DIRECT VENT

6

conce

6

1

ntric

Concentric termination assem

(sidewa

9

en

Ve

nt

9

10
II

12

12

12

13

IS

IS

IS

16

16

18

p 19

20

and a

nections

DIRECTEXHAUST&DIRECTVENT .
Follow

termination instructions . . . . . 48

Installing vent a
DI

RECT

DIRECT EXHAU

ope

nings

Combustion

Siring

combu.<Jtio

Special constderations. . . . . . . . . . . 49

9V90+ boiler

tn room . . . . . . . . . . . . . . . . . . .

Air openings . . . . . . . . . . . . . . . .

CV90+ boiler

roon1 . . . . . . . . . . . . . . . . . . . .

DIRECT EXHAU

- Vertical with

.............

ll

or vertica

ir

pipi

..............

nd

EXHAUST

..............

ai:

r provision. . . . . . . . . 49

n air openings . . . . . 49

WITHOUT other appl

WITH other

DIRECT EXHAU

22

23

23
23
23

24

24

29

29
29

30
30
30
30

·

34

35

36

37

39

Gas piping

Connecting

Natural Cas . . . . . . . . . . . . . . . . .

Propane Cas . . . . . . . . . . . . . . . .

Wiri

ng

Field wiring. . . . . . . . . . . . . . . . .

Sta

rt-

Freeze
Clean system to
Water

Antifreeze . . . . . . . . . . . . . . . . . . S9

F

lll

and

Use

inhibit

Check/Ve

Check

Check

Verifygas/airorificeplate . . . . . . . . . 61

Check thermostat circuit(s) . . . . . . . . 61

In

spect/fiJI condensate syst

Final checks before starting boiler . . . . 62

Adjust

Aju.•

n boiler control

Bo

iler

st

art

To

If

boiler does

Ch

eck

Cas

vatve
re.tONLY
Final checklist

.............

gas

suppty pi ping. . . . . . .

...............

up

...............

protection (wh

remo\>e

chemistry . . . . . . . . . . . . . . S9

test wa.ter system . . . . . . . . . 60

or

supplied with boiler . . . . 60

ri

fy water chemistry. . . . . . . 60

imllit:or

boiler control srttinp . . . . . . . 62

c.oncm

for

gas

leaks. . . . . . . . . . . . . 61

Eco

nomy settings. . . . . . . . . . 62

the

boiler

nots

system

and

adjustment - attitude

.................

...............

-

Boiler

ll

with 3"

41

-·

43

3"

45

bly

l)

ng

........

and

boiler con-

47

48

48

air piping . . . . . . . 48

ONLY

. . . . . . . .

48

ST - Boiler room air

49

iances

50
50

appliances in

ST - Sidewa
ST -

Ve

rtical

ll

•..

..

50

51
53

54

S4

SS
SS

55

S6

59

en

u.W)

. . . . . . S9

sediment . . . . S9

tnr:

ion

an

rualy

. . . 60

em

. . . . . . 61

setti:nSJ>

. . . . . . . . 62

.............

tart correctly

boiler after start·up

.....

O\'ft'

62
62

..

62

S.SOO

63
64

Manual

Department of

IBC

(Sequence

Operating lnstrustions

Annual start·up a

nance schedule . . . . . . . . . . 68

Annual start-up . . . . . . . . . . 69

Address reported problems . . . . . . . . 69

Inspect boiler area . . . . . . . . . . . . . 69

Inspect boiler interior . . . . . . . . . . .

Inspect condensate drain syst
Inspect

Inspect gas piping . . . . . . . . . . . . .

Inspect

Check water syst

Inspect expansion tank . . . . . . . . . .

Inspect
Inspect
Inspect boil

Inspect igniter . . . . . . . . . . . . . . .

Inspect t
Inspect
Inspect
Inspect blower mot

Inspect oiled·beari:ng circulaton . . . . .

Inspect supply temperature sensor . . . .

Inspect boiler relief

To

comple1< Annual

startup

Review

Se

rvi

ce

Cleaning boil

To remove the blower assembty . . . . . 73

To

dea

n heating surfaces . . . . . . . . . 73

To

dea

n

To

replace blower assembly

Inspecting and

Tro~eshooting

VERIFY
SERV

ICING

Before troubleshooting . . . . . . . . . .

Check the following . . . . . . . . . . . .

Checking the air pressure

Ig

niter

....................

Gas

Valve
Blower
Thermal

Return temperature sensor . . . . . . . .

Suppty temperature sensor . . . . . . . .

IBC

(integrated boiler control) . . . . . .

IBC

indKat

IBCin<iiolt«

Installation a
ce

rtificate . . . . . .

Replacement

Dimensions

Handling ceramic fiber
glaoo

mat

NOTES ..............

Energy

of

eon-.>liance

operations)

..........

.......

nd general maint

e:n

l . . . . .

all

pipi

ng

for

leaks . . . . . . . .

the

water system. . . . . . . . . .

e:n

l chemist

air

openings . . . . . . . . . . . .

ven

t system and air piping . . . .

er

heati

ng

e:nlpe:ral'Ute

additional

gauge5

and
with

conuok

. . . . . . . . . . . . . . .

or

checks . . . . . . . . . . . . n

owner.

& maintenan

er

heati

the

burner

deaning

ry

. . . . . .

surfaces

mi.xi:

. . . . . . . . . . .

valve

Slan·up,

. . . . . .

ng system . . .

and

cutotfs

. . . . . . . . . n

perform

. . . . . . . . . . . . n

ce

. . . . . . 73

ng

surf:lces

. . . . . . . . . . . . 74

. . . . . 73

........

the recuperator 74

..........

PROPER

Housi

fuse

OPERATION

.................

. . . . . . . . . . . . . . . . . .

ng

. . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

or Lights - lockout modes. .

l

iglu>-non·~m<><l<!

nd

service

parts

and

ratings. 1

AFTER

switch

. . . . . 76

. . . . 91

and

fiber-

erials. 106

. . .

.

65

66

67

e-

69
69
69
69
69
69

70
70
70
70
70

71
71
71
71

71
71

74

76

76

76
76

77
77
77
77
78
78

79
79

.

79

90

02

107

4

Pan

number

SS0-142· 783/1012

GV90+

Series

2

OAS·FtRED

WATER BOILER -

Boiler

Manual

Please

Hazard

The

bring attention

to i

!A

NOTIC

IAwARNIN&l

NOnCE

definitions

following

mportant information

CAUTION 1 lnd

E

read

defined

lnd

perSona
damage.

lnd

perSonal i

damage.

minor

Jndicares

Opt-ration o r maintenance th
no

Installer-

man

boiler> before installin
gi

Uller-

he-ating installer/service technician.
Jn:f'onnation

User - Ha\'t this

qualified service technidan, at
fajlure

sevtrt personal injur

da.mage.

W~itt

the In stallation certificate

terms

to r.he prestnce

icares pr

l injur-J'•

icares pr

icares presence

ptmna

t related

ual

and

.. ·tn.

This manual

to

in the CP numbtr

before

are

used

of

concerning

t.Sence

of

dearh

t.Sence

of

njur)

'• dearh

of

l inj

ury

speda

l

in

to

ptrso

nal inj

Read

all

all

other in

ManuaJ fo

comply wi

throughout

hazards

boiler serviced/inspected by a

y,

of vari

the life

of

hazards thar w

or

substa

hazards that can cause

or

substantial proper

hazards that

or proptrty

srructions

ury

instructions. induding this

for

g.

Perfonn steps in the order

is f

or

r your referen

th th

death or substantia] proptrty

in the space provided on

on

on insrallation.

ar

are i

or

proptrty

mation

use

only

lea

st annually.

e above could result in

page

this

ous risk

the product.

lll

nt ial

will

damage.

mportanr

shipped with

Refe

90

shown.

\Vhen

call

ing

or writing about the
have the boil
label and the

Consider piping and installati
boiler location.

Any claims for damage or shorrage in shipment

must

company by the consignee.

Commonwealth

When the boi

l-er

M..,.chu.setts, comply

This produ

fitter

If antifreeze is used, a reduced pressure back-flow preventer

d.,;ce

tf sidewa

ct

must

.

sha

ll

be

JI

\.'tnt or venr/air is insralled>

er

model nwnber

CP

number

be

filed

immedlatelyagainst

of

Massachusetts

is installed within the Commonwealth

with

<he

be

installed by a licensed plumber or

uStd

.

from

following.

boiler-

from

the

the boi

on

when determining

the

transportati on

see

instructions on

page 34.

proceeding

~WARIM

manual

cause

or

can cause

by

a

r to User's

ce.

if

not already

boiJtr

le

r jacket.

to

lt•ttls or

sevt-

rt

property

sevt-

rt

ty

bur

damage.

th

qualifi

ed

Please

raring

of

gas

When ..,,.,.;cing boiler-

To
before performing maintenance.

To
performing maintenance.

This boil
materials.

on

Boiler operation -

Do

to

Should

tMit

sup.
at

Do not

woter.

e

cian to inspect

the control system and any gas control that has bft.n

under

Combustion air -

DO

It a rltk

Carbon monoxide detector-

Fo

tor is requir
oxide dttecror must be wired
circuit

Fo
that
is

Boiler water-

Thoroughly

neo

exd1anger
due

Do
compounds
system

property
LNkoln

to P<8Yenl

In

wat-er will
exchangers reduces heat transfer,
ri

als,

by

Do

ca

Freeze protection fluid• -

NEVER

Use

systems. Foll

manufucturer.
placeme
m

I

Failure to adhere ro the guidelines

page

can resu

Cleath

or

avoid electric shock, disconnecr electr

avoid

severe

er

contains ceramic t'ibtr

Refe

1

.

r to the

06.

flow

page

not bloc.k

boiler

""erhNUng occur or g

off,

DO

t

~

ci

NOT

rculator.

P.Iy

ll in

severe

substantia] proptrty damage.

burns, allow

WARNING

of combustion or \

personal i

boiler ro cool before

and instructions

..

tum off or disconnect electri

Instead>

sh~r

off the gas supply

a l ocanon externaJ to the apphanct.

UM

thla

Immediately

wate

r.

NOT Insta

of

combustion air contamln.Uon.

r

OII'Cid

Exhaust uni

ed

as

the boil

r Direct

stro

V•nt

i.s

wirtd on the same electrica

ngly recommended.

flu

ted )

to

removeS<'dinlenl

can

to sedimtnr.
not

lL~t

JH:trole

in boiler

may

bedamage<t.

call a

tht

boiler and to

ll

combulllon air Intake whwe there

in the boil

er.

units, a carbon monoxide dttecror

sh

the system

be

damaged by build-up or cor

um-based

S)'Stem.

boiler H any

~h

qil3lifi

ts,

a carbon monoxi

er r

oom

..

ed s

rtp

l.act any

. The carbon mon-

on the

l d rcuir

(without boil er con-

TbehbUI-ellic.iencyheat

deaning

Gaskets

This

can

r

esu

damage.

boiler

0<

piping ,.....t

• ciOMd-toop system. Contin

make-

not

n cause heat exchanger to crac

only

sr.alling the n

moke-t~p

rtduct

an

<I

cause.s
up

water

add

cold

u.se

automoti\·t or standard glycol antifrtt:ze.

freeu-protectlon

ow

nt

boiler system that has used gl

woter. Use

boiler life. Min

tanure. Addition

can

cause intern

w.ter

to

aU guidelines gi,·

Thoroughly
ew

boiler.

be

repeiN<I

thlo boiler

ual

eraJ buil

overheats the mate-

of

oxyge

al corrosion.

hot

bolter. ThennaJ shock

k..

fluids

made

tn

dean

br.

ana flush

on

thi.s

njury,

ica

J supply

and

fiber~lass

<entilation

aupply

air

11111

to

cal

_.,under

ervice

techni-

va:

rt

of

de

detec

same

electri

cal

as

the boiler

ros

ion

or

and seals

lt in substantial

staling

in

the

ot once

ONLY

fre.sh

make-up

dup in heat

n carried in

for

hydronic

the antifreeze

apy

)'cO

re-

I before

-

Part num

ber

550-1+2-783/1012

5

GV90+

Series

2

oAs·FIRED

WATER

BOILER

-

Boiler

Manual

Prepare

Installations

Lo<a

l,

srat:t,

provincial, national codes, J

National
Standard for Controls

Boilers,

National

For Canada only: Bi49.i or Bl49.2 Installation Code

Canadian

The

GV90+

perrormance criteria when boiler underwent tests specified in

-latest

1

MOneE

High

GV90+

See

Figure 1 for estimated

input. Multiply the boiler

est

imated high aJtitude i

wi

ll

also

fur

ther info

No mo

s.soo

be

musr

kit instructions, page 10. Note that

checked (and adjus

N

OTICE

Fuel

ANSf/ASME

Ele

EJectricaJ

boiJt r

edirion.

1 For

rhe special instructions located
Insta

from

Al

bo

substantial proprrty damage.

altitude

boil6'

<Mirols

h

ave

a min

rmation.

difications

fee

t above

changed

DO

ar

for DIRECT

altitudes a1x

boiler

must

Gas Code, ANSI Z223.1

ctrical

Code

gas

manifold

th

e Commonwealth

ll

the boi

ti'lpplng

lowin

g.

iler faiJu

Installations

•utofililitAIIy

or

impact on input.

to the

St:a

level. For higher

to

aspttial

ted

if

NOT oldowall

alrirud~s

follow these

and

Safety

CSD-t, when

Code

Pa

rr 1 and any local codes.

and

kr

so

control S)'Stem componrnts

or

spraying water

these

compone

rt,

resulti ng in

inp

ut

at

sea

level

input

nput

. Note that the length

boiler should

high altitude switch.

necessary) followin

vtnt

abo\re

s.soo

VENT

app

we

s.soo

fee

location

codes:

aws,

regulations

- latest edition.

Devices for Automatically Fired

r~uirM.

con

tro

ls

m~

of

Massachusetts, read and foll

on

page 34

or rak'l

nts

to

become wet

severe

personal i

todutt input

altitude as a percentage

b)• this

Refer

be

nece

e-levations

the

gas

DIRECT EXHAUST

feeL

Si

lications (

t

wit

ptrc~ntage

to

the vent

ssary

. the air pressu

Refe

\<alve

outlet pressure

g insrructions on page 63.

dewa

JJ

ducted

and

and

safe

lighting

of

dur

njury,

h

ina~ing

of

the •tenting systttn

supplement l'

for

installatio

r ro the high altitude

APPUCAnONS

venting is only

combustion

ordinanc~.

CSA

C22

.1

and

other

ANSI Z21.13

this manual.

~

ing Optrntion.

cou

ow

protected

ld

cau~

a

death

or

alritudt.

of

St:a

level

to

obrain the

..,r

ns

up

to

re

switdl

mu~

be

allowed

air) nt

Figure

Figure

0

~

1 Estimaled GV90+ input at altitude

Altitude

(

fee

t )

1 000
2,000
3,000
4,000
5000
5,500
6,000

7,000 77

8,000 74

9.000 72

10,000

2

Service clearances (recommended)

%

Sea

leve

97

93

90
87

83

82

80

69

l

Input

TOP VIEW

W"'l

~

6'

i

ml"

36'

...

i%

-~"""

lir

8GIIL>r

rront

:w

••

I

W•ll

cr

oo:nn.ctlo-1!

'

-··

~

,.

....

>

Ve

M

OnCE

Service

When possible. insrall
shown in Figure 2 for best service

nr length

caJiyderates ro compensate for pressurt

See

the

alrirude
\'ll

]ue show-n in Figure 1

clearances

aJso

affects boil

d~rate

values

inst:a

Uartons, mulriply

GV90+

bo

given in

09

ilers

wir.h

access.

er

ro

Flooring

The

GV90+

bur

mu.sr

6

boiler is • ppr

never be install

Do n

ot

ins

used.

Fi r

~

or

subsran

ove

d for installation on combustible flooring,

ed on carpeting.

rall boil
can resul
tiaJ

er

on carpeting even if foundation

t,

causing severe personaJ i

property damage.

input-

Figure

ihe%

d~ermine

dea.rances at least as large lt.'i

the boil

&oss

109,

in

er

through

page 103. For high

Figure 1 rimes tht'

input

vs

sea leveL

njury,

auromati-

the

vcnL

death

i.-.

::1

3:

FRON

36"

rln

T VIEW

C~lna

R.,.,

hool

Fl

..

..-.

l•.an

num

l

I

~

-

••

!

Ql

ber

550-l-42-783/10

-·

s·

-

~-

j

12

GV90+

Serie

s 2

fiA!i

-fll

~o

w

_".,.

IIOlL-1!11

- BaU

er Manua

l

Prepare

boiler

location

Foundati.on

Providt a .sQiid br:lck

is

possible:

When

the

floor ca.n

Whto (hr:

boiJI(-r

When a high

bigh

c:-nOug

-as

the

t.Xmd(nsat~

Figure 3 Minimum fll<J!ldalion dimeosians (inches)

Boll

or

model

G~

GV90+S I GV90

• lnCI'tllk

e;mdcmioll

vf

/

GV90+4

heighl

!rnp

condc"nsate

Residential

or

<Q.ocmo

becoll)f

mbuntin_g

-profile

h tl:\at lhr: GV90+ c(mden,sat,t

condensaie

pump inl

w L

11!;

+6

16

if

nttded

iltlil<U~

puJnp.

ilHilluv~

v/Jttn

garage

foundation

flood~

ak:il

is n

ot l.e're

pump

t-r

c(ui.ne<tio

H'

LU

auo

2

2

re

inlet

301'

371'

u&erd.

Installation

~

pad

it

llny

l.

is u

sed,

provide a foWldaiion

cOnnectil)n

u.

-------=

~

---~--

oi'

is

at

the

least

(continued)

Figu

following

as

hfgli

""""

A ..Arta

+-·

~

::..,

B

C !ProVide 1,2) Fresh ait

re 4

Min

imum

ci~(J$

clearancas

mended

ure 2, page 6, inslali

$ervice

TOP

me

VIEW

~

...

4_:..

m

in

Fr

ont

adjact:n~

and

m\!S~

f

ot"

.se-rvict-.

iNo

o

tJ~r

etc

.)

n'my

..Aca.~DOOR

l~mst

1 5q. inch p

«>

allow

for

...

pplilnC'I:'

l,t

m.JwHel;l

IY

er

ac:-cos

~(tval

or

a.

in

ilh

fft'.AA

~

pccios<-~odl

UM)U

- whoo

lliSs than

clearances ol Fi

rocom

as

shown below:

Wall

t

10"

min

f~

El<>iler

t

op

Wal

l

d<l(tl'

mus

()

( l,he GV90,..boile.r

i.r

mowr

th~

samt

nir

upenin~tr.:

Btu'l1

.

~

lko

acct!1~ible.

(~x

haust

fpacc.",

Wfth

or

bolter input

•

1

l

1ln,

g-

al.

Precautions

Take the following

residmtiaJ garage. If the boiler is located

Z223.1,parngraph

Mount

garage ro assutrt the burner

18

Locate
\'fhi

the

inc.bes

or

de.

Minimum

IAWAHNING

I

Alwa

ys

provide ar least screwdri\'fr clearance

for rt:mO\'al

If the boiler c-annot

and iso

lati

an adjacent area.

The

space has

unpiped and

sptcial precautions when installing r.he builer ln u

5.1.

9:

bo

lltr a minimum

abO\~e

the

fl

protect

the

oor.

bolktr

of

18

and

ignition devices will

so

it

clearances

You

can

in.s

mll

GV%+

ure

2.

page 6 recommended servi

smaJ

Je:r than

I

nstallations with

ure

2,

shown in Figure 4.

of

fronr

on

valves

to

~

shown

page 6 musr ha\'f air

pane-l

be

serv~

so

it

can

be

equ

ipped with a

moved.

boiJers in spaces small

in Figu

clearances less th

for inspection

In

be

sl

in

a residential

Inches

cann

re 4.

openings si

place

id out

door

garage)~

above

the

be

ot

be

damaged by a muving

ce

dearances.

an

shown

ud

and

to

jackrt front panel

and

minor

sen·ice.

. pipe

the

boiler

of

rhe

space

and

so

boiler

can

ANSI

floor

of

the

no

J~

thon

er

thA

H Fig-

but

n

ever

lP Fig-

l

tKat.ed

St."t't'\'f'

with uruuus

krvic«< iu

be

ue<:cs.'icd.

as

SI

DE

VIEW

Coll

~

6

1'

mll

ll'

l

- Accessdoor

lhg

t ,.

+

m.,

1i

4.

co:::

11

6

l'I'W(

-i:

l

f'

NOllCE SPECIAL

FOR

AIR

~-lith

dta

&t:tlfic.e dt:tr'ances {Fig

no

klu

occess

s

door

LWO

iti.r

Each

ltl)t-nirtg, mlJst ba\

l

es~

t.lun J

iurut

uf

DO NOT

given

ure

60,

-

...

£

Flocn

OPENINGS: Flif

tan

ceo.

than shown In

must:

ypw.io&S

~uttre

tt,e-

GV90+

apply

In

Aguro

pa;.

50

Bo11~l

"

&i

dll

REQUIREMENTS

lt.'.-t

than

ure

be

lht

.

Agure

provided,fitted

a5

shllWn io

t:

inch ptr I

boilc:r iu the spacr.

air

aptnlng

42, page

it;,tiill•ti<lill

rec~:J"mm

2.

pagt 6).bul

.i

ft«

36

~

,r

"""

tndtd

4 - An

wlth

Fit.'l.trt'

nl'ea

nu

OOtl

Btuh

alzH

or

FJg

4

~

..

Part num

ber

550-1+2

-783/10 12

7

GV90+

Series

2

oAs·FIRED

WATER

BOILER

- Bo

ll

er

ManuaJ

Prepare

Check

orifice

The COf'l'tltCt ortflce plate must be

will

property damage. The

gas

the

plate -replace

resuJt in

ortflct

propane.

Natural gas:

For n

atura

l

gas

installations.

marking.

stamped with

saler. The boil
stamping.

It

must

anothe

er si

Figure 6.

be

the

r si

u,

7.t

is sramprd where

Propane:

For propane insrallarions,

with

the

redlwhtte

white plate boil

The

boiler

siu

ing. Figure 6.

Also

fill o

ut

lefrside

of

the jacker,abovethegas inlet opening. as shown in Figure 5,

plate

er

siu

is

co

is stamped where the

the

propane

boiler

severe

persona] in

bolltrls

plate. h MUST BE CONVERTED

Inspect

same

obrain the cor

nplac•

as

the

the

boiler

the

sUver

rtct

the

sliver

(continued)

if

necessary

used. FaiJu

jur

y.

death

or

substantial

shipped

size.

plate from

..

X

"'

with a natural

gas/air

If

the

ortflee

orifice

your

is shown in rhe plate

gas/air

orttlc•

rt

to

to

plate

who

, per following instructions. Ensure the

rrtct for the

label

in

GV90+ boil

1

'X

..

th e

com-ersion

er being installed.

is

shown in the plate stamp-

kit

and attac.b

do

so

uu

plate

le-

plate

r

~

to

the

Figure 6 Check
A

:R.emow

p

an~l

to

.m

m

~ide-Qf

housing.

B Co.

mp

lcte1t,el'fopane

connrsion label ind

«1

Wit

h

th.e

kit.

Insr.a.IJ

ld't t

ida

is

~the

on the skid

yo

u

~

ri6ce

11cce658t

Figure 6 Follow insv

,

f;Joil~

8$

~love

chocked

plate and

y.

j

s.cktt.

&oot

aa:~$

thf' bot-

t

he

bl

COP\ttniQn

labt.

l oo. j.:td:d

11$

Mlawn.

oo.lts ba

shown,

thr

n!pl.aoe

gas

or.

for corr

ect

ower

ud

-

ck,.

!Jn

til

g;oi/mr

it

if

uctJons to check

ijice plate

gas

o

r~ice

rx·

= boiler size)

plate

0<

replace

Orifice plate installation, when required

AcctsS the bottom

inspect the plate only.

To

musr read rhe same as ·the boil

Boltr

model

GV90+3
GV90+4
GV90+5
GV90+6

To repl

ace r.he plate . using a maooal

Figur

e6:

1.

Loose

n screws 1

2.

Remove

3.

PuiJ

the

4. Slide in the n
propane plate

5.

Rep

lace screws 3

formly. DO NOT overtighten. DO NOT exceed 40 inch-pound$

torque.

6. lknd down plate label rabat score mark

of Figure 6. it

comer

jAwARtM

I

of

tile blow·

Nat ural

and

er

housi

read

the

er Si7.t

gas

martdng

NG3SEC
NG4SEC
NG5SEC
NG6SEC

2 two full

ng

as shown in Figure 5.

marking

and

on

fuel, as foll

Ptopane

scn

wdrtver

turns.

the

screws 3 and 4.

gas/air

oriffice

plate

forward

ew

plate

as

shown in

nut

go

next to

and

4. Tighten

em

10.

DO

NOI'

use

electric

or tighten

move
onl

y,

usi

ng

4()

inch-pounds. the threaded holes could str

causing

an

properly seal the plate
leak. causingse\rere person

property damage.

r.

he gas/air boss saews. Hand-tighren

manuaJ

SCTtWdri\·er.Shou

inadequate

to

remove it.

Figu

re 6. T

the

bloww housing.

all four screws securely and uni-

as

shown in lower right

or

pnewnatic screwdri\·ers

ki

seal

of th e

orifice

to

the housing could

al

injur

y,

death or substantial

plate edge. It

ows:

mar1dng

LP3SEC
LP4SEC
LPSSEC
LP6SEC

or

nut

Qotver

he

nd

side

rhe torque excted

plate. Failure

resu

to

ip out,

lr in a

.

of

see.

a

re-

to

gas

1-4

.!ia'twi - follow

S

C:a~a.il:'

manifold

6 Fn,nl

7

8 Ptopule Otifict plate.RBDaoe6ideandWHIT.Eon

9

1 0 Orificepbte after bendtng along

~tion.,

$Me

$bcw.ttt mu.tt

llibtf

fll.de

4tbi:r (

ttd

Natw-a:lg:uotifio:e

\liu"b

lt

wl~

lt•itrt~t:Ubnt

lO

skit

r 1At

im.UJ

bouam vi

ew,

po;lnt

t

unl

~

n\11St

~

plate.SIIYE!R

IM

(I'Wa

WH'ITI:-d

dw

fot

l

~lns

campon

nu

dtull.t omiJkd

rd

-aif lltlt1 h

~rhou..~

de

Kote

ttte-

for propane

mack

and lir;htal.ins;

WARN

-

l.tbel

lNG

gM

th~

111

8

P3n

num

ber

SSQ-142-7831101'2

GV90+ Series

2

oAs·FIRED

WATER

BOILER

-

Boiler

Manual

Prepare

In

sta

ll

cond

I.

Btlo

re

plac

ing

lint, shown

Slop 1 Attach the

Step

2 Slide a

Slop3

Slop4

Step

5

IA

WARNNG

in Figu

nip

ple

(B)

scTtW

dra

in nipp

Slide r.he end

end

of tibe

Feed

the in-line

nection (D), guiding the

densate

Press

the in-lin e

(D)

and

Then tighten tl ie

The

flue

end

of

tile condensate drain n

Slide t

he

and i

nt:o r.he

vided

tc>

trap

tee

Sl

ide

l'he

con

densa

(E). Secure the condensate trap hose at each end with

hose

damps

Choc:k

I

Before

distttnce from the con

of th.e boiler mounting ralls. When the boiler is place io

position, rhe condensate

the

condensa

densate p

if

nt<tSSary.

the

en

sate trap

the

boiler

re 7. Items shown are pr

flue

draJn h

.

driver or

le (G).

boiler

in

pos

'irton,

ose

(C) to the in-liue

prnc

iJ

install the

O\'

through

of r.he screwdri\'fr or ptnci l inro the

flu

dra

in nipple

thro

drain

U-cl

the U-

e draJn b

ugh

amp

two

ose

(C).

flue

drain

(A)

assembly

flue

drain

hose thro

(G)

with r.ht screwdriver or ptnciJ.

flu

e draJn (

the seal r

flue

bose

(C) sho

(F) over the condensate trap tee (E)

holes

damp

A)

into th e

ing

until it reaches

connection b

uld

now

ipp

in the rai

and

l.

righren ro sec

ose

extend

le (G).

Atrach the two nuts pro-

ro the raiL

ends

of

the

te drain n

tho

rotating the boil

ipp

le (G)

(J}.

holght

ump

o1

te

pump

is used). Increase the foundation hefghl

condensate

trap

and r.he condensate trap tee

th

o condonsato

er into

densate

tee

inler connection

hose

pos

t~ oud

outlet musr

(continvedJ

condensate. trap

ided wi

rh

the

flue

drain

the condensare

open

into

the

flue

ugh the con-

flue

connection

the

srop

damp to

ure

ition,

secure

down

past

the

condensate

(H)

on

to

trep , ..

me

asu~

~

ro the bottmn

be

higher Lban

(wh

en a con-

boiler.

con-

.

.

the

the

tht>

outlot,

lhf"'

Figure 7 Insta

A

lo-Outdnin

B

Au..e

draln

nfpplt

c

Flu.t

dni:n bose

'f1u.t

c:anne:.don

0

E Co

n.;Jcnsalf'

F

u~~ud ooL~

•b

-)

G

Con

nipPle

H Con

H~·

J

tnq

den~itt

dn.lri

denAuo

lnlf'

d.amp~

ll

condens<~

•

let

(oot,

hcl.l;e

l

e

trap

Fint.hed

MMtnbty

Part num

ber

550-

14-2

-783/10 12

9

GV90+

Series

2

oAs·FIRED

WATER

BOILER

-

Bofler

ManuaJ

Prepare

Install high alti

when

1.

"IA"w"AR=

2.

3.

required

For installations at altitu

a. A special high altitude air pressure swirch
b.

The

gas

adjust~

IING

=~I

Failure

necessary>

or

gu

Obta

in the GV90+ hi

distributor. The hi

pressure switch.

See

Figure 8

a. Remove the

swirch

spade

b. Remove r.he factory-installed air pressure switch (loosen rop

screw and remove bottom screw holding switch
tt'r'iO

r panel).

c. lnsraU r.he high alri

tion.

d. Cart full

on
$hown in

e.

Replace the

swarch

)• replace the

the hose barb cloStSt

spade te:rmi

the

tude

(only above

de more th

valve

outler

if necessar

substantial

idelin

(sw

Fig"~$.

y)

per the instrucrions

ro

check

couJd

proptrty

e$ given

gh

altitude kit from

gh

altitude kir contains the high altitude air

itch shown with wi

two

(REO)

te:rmi

nal

r.ude

hOStS

Th¢whi!¢

two (RED) cont

naJ

boiler

air

pressure

an

pressure

gas

result in

in this manual

seuing must

valve

oudet pr

St'\'ff't

damage. Carefully follow the

res

contro

l wires from the air pressure

S.SOO

removed}.

(continued)

switch

5,500

personal injur

)'Ou

feet)

feet

abo\re

i.s

r~uirM.

bt

checked,

on

page 63.

essure and adjust,

r l

oca

l Weii-

sea

s.

to

jad:er in-

air pressure switch in the same loca-

on rhe

new

switch. with the

to

the electrical spade connecrors. as

hQI¢g~on !h~

rol wires on

s.

o!'h~rh~bar\>,

r.he

new pressurt:

level:

y,

dearh

Mcta

rtd

and

if

in

hose

Figure 8

1 lntmtw

2

3 Air

4 WHrTEb

5 ReD-
8

Figure 9 Follow instruct

Air

pressure switch

poliJII!:I

COl?

J~1

ld1

sid~

panel

pres-

tuft'

!M"itcb

oilli-

MoUnlin.l-i.::r"""

shown

bgtow

moun~ng

ions

to perloon the steps

Rotate

!A

CAUTIO

After installing condensate line. inspecting (replacing
gas/alr orifice

the boll
Figu

re
These pantls may
completed.

the boi

N I Boileris shipp<d

and rora

and

t'r'

near its position.

9 shows

Bo
may have
rake pr
will

ted

Installing t

r.he

boiler with

bt

left

iler

i.s

h

ope

resuJt in

ler Into

eavy

sha

r precautions when mO\'ing. Failure

position

on

back side.lt must

inro correct position.

he

high allilude kit (

r.he

front and

off

if desir

ed

unr

il

rhe insrallarion h

and contain

rp edges.

St\'frt

s some sheet metal parts which

Wear giO\'fS

persona] in

jur

top

when h

y.

death

If

property damage.

Refer

to

Figure 9 for placement sequence

1 W

ear

hNYY gk>ves - cartfully roratt

base rail

2 Clip

sembly. Remove

3 Attach the )ack

pr

legs.

the

shipping strap securing the skid

O\<ided

in the accessory

th~

skid and strap.

tt

rtar

panel as shown using (4)

bag.

as foll

r.he

ows:

boiler over onto its

to

the boiler block as-

b<

taken

off

skid

if

necessary) r.he

required), m

panels replaced.

and

or

substanri

II

Ox

ove

as

bet-

ling and

to

do

S6

al

~»screws

n

10

P.an ntunber SS0-142-7M/1012

GV90+

Series

2

oAs·FIRED

WATER

BOILER-

Boiler

Manual

Prepare

Perform

Pressure test boiler

no

ted

pro<t<ding.

IA

WARNING

Prepare

Stop 1 Connec>t a

Step 2

Step

3 Rtmo

Step

4 Connect a nipple and shuroff

hydrostat

bel

ow)

or electrical supply. Remo

Use

I

bollar, using
interior pipi

piping connections to prevent them from

caus.e

boiler

for h)rd

Connect
also

be

ture gauge

nection as shown.

connection on the 1"

alr dwilng tbe

the

befor•

two

wrenches

ng

damage

lor

test-see

bose

from water supply to

rosraric test.

h

ose

ro boil

used

to

dra

ve

I" nipple. I" tee, bushing

from

611. Valve

boiler.

boiler

ic

pressure

attaching water

ve

wh.en dghtenlng water piping

one

of

rhe wrenches

from turning.

to boiler

Fallu~

components.

Figure

or

gas

jacket

to

to

10

test

(continvedJ

fill

Hose

is nor included with boiler.

er dr

ain

vahre.

Mak

e sure hose can

in boiler after test

and

pressure/tempera-

accesso

ry bag. Pipe to boiler supply con-

Use

pipe do

tee

pe

sparin

gly.

valve

to system supply

.

This

val~

w

ill

be

and nipple are not

piping

top

panel before

preve

nt

support

turnin

aod

drain

used

included

(exctpl

the

ro bl

as

at

boil~r

the boi

ll"r

goo~.Jid

boiler

eed

"ith

Figure 10

Pip

ing connecli

ons

for

hydr

osta

lic l

esl

Step

5 Connect a nipple and shuroff

Step

c-Onnec.ti.on

bleed
wi

th boil

6 Insta

the rear boil

at

drc.ula

alr

during the

er.

ll

a

o/4

• pipe plug in

er section, as shown. Plug

boiler.

Fill and

I. Connect

2. Fill boiler wirh

3. ·

4.

5.

6.

IA

WARNNG

1.

I

AWARMNGI Leaks

t~j•Of!Hj;l

pressure

611

when

wate

\'lllve.

Close

bl

eed val

Slow

ly reopen drain val

(or

1.5

times boiJ

75 PSI G)

Tesr

Make sure
out test.

Ls

reached

at this pressure for no more than

I

Do

expa.nd
personal injur

co~rant

Check

age

Do

pounds
occur, r

test

water supply through drain v

wate

r (

be

r flows from bl

ves.

tr

rel

on

nolleave boiler

and cause excessi

gauge pressure has

fo

r l

eaks.

mu

st

be

boiler, resulting in substantial property damage .
not use

petrO

in boiler

esu

lting in substantial properr,• damage.

valve

to system rerum

tor

flange

. This

valve

will

fill

Valve

and nipple are not included

the

rtlitf

va

h·e opening. rop

is

not

alve

,ltem

sure bl

eed

valves

at 4 and 5 are op01).

eed

valves,

ve

(item

2)

ief valv

e setti

<he pressure

unattended. A co

y,

death or substanti

Repair if

rtpa

ired aronce.

leum-based deaning or sealing

sysrem.

shur off water at

until test pressure of 45

ng-

NEVER

gauge.

10

minutes.

ld

ve

pressure, resulting in

al

property

been

maintained through-

found.

Failure

t:odoso

Severe

damage

be

1.lSled

incl

uded

2.

MORE

ll~ler

fill

dama.g

can

to

boila

to

of

wi

th

dta

ln

PSIG

than

rould

Si!\'t're

e.

dam·

CQm

wm

-

Drain

2. Dr

3.

4..

and

remo

1.

Disconne.:.t

al11 bobt:r

vidt.s

best

access

h~

after

cl.rnining..

Rto:m

JI)\'e l'lug {itmi

lso

la.tion

viti

boiler's temp«ature

ve fittingo

fi1l

water

hose

at drain vahll:

to dmln.

6)

from rditfvalve

\'ell: at<"

m.Luif'C!'d

Sc.'nSor.

from

water source.

or

out

hose, w

dost

drain

valve

rappU\8;

10 enable servicing

hic

hever pro-

tu

ld reJnovt

uf

th(

Part num

ber

550-14-2-783/1012

11

GV90+ Series

2

oAs·FIRED

WATER

BOILER

-

Boiler

ManuaJ

Install

water

Use two wrenches when tightening water piping

boller, using one
interior
piping

cause damage to boiler component:s.

The

be

to

This is
ci

cuJators.

i

piping

ronntction.s

cast

iron

kept

al

or

prevtn.t possib

done

rculators.

Fa

njury,

death or substanti

General piping I

Minimum
Figure

Additional

Follow
ASME
llmtt
standards

lnsta
and

\\fi

rro

Set

limit conrrol

pipe

siz:e

11

Provide

below (based on 20'F tempera

GV90+ 3 or 4
GV90+ 6 or 6

ing standard industry pracri

or Canadian

may

be

to determine·

JJ

a manual r

th

e isolation

re

the manual

l.

the manual r

boi

Boiler

limit

net<led. Consult locaJ

loop

controls

r

equir~men

if

e-set

valve.

reset

es-et limit control at least

St-rting

piping

of r.he wrenches

from

turning.

to

pre\re

heat exchanger r

above 1

DO

llu

nform

for

ler loop piping no smaller lhan li

needed.

high temperature limit

(maximum setring

4WF during

ility of

corrosion

auromaticall

NOT

~

ro comply could result in

boiler

pipe

limit in series with the boil

y, using the boiler's

rtmove

al

ati

on

loop

size,

ces.

if installation

ts,

an

additio

r~ui

Wir~

as

to

prevent

Failure

ro support the boiler

nt

them from turning could

eturn

temperature

all

times

due

to condensatio

or

ramprr

prope-rty

with these cir-

k\'t'rt

damage.

piping

ture ri

se)

Minimum

1"

i.s

to comply wi

nal

high temperature

remen

ts

for other

shown in Figure 67. page 56.

between

er limit con·

200F

above the boiler

2200F).

the

of

optrarion

interna

pe-rSOnal

sted

the boiler

at

boiler

mu.s~

n.

th

codes/

Air

separator

lnst•ll

ali

air N)>lrator

rnanua

l.

Fur

.single-1.onc--

in

Lht-

rrlllrn piping

aiJ.ows

m01,11lting

off

of

the

In

st a

ll reli

l

L

ln.stalJ

1. Connect discharge pip ing 10 safe di

tb

llow'i

r.be

s<poararor

ef valv

t<litf

val""

ng

guiddblt<-$

Figure 12 Install

(

4}~,.\i

.. ,

..

j®

,.....

" r

.syskr

a&-

:shown

aut.omatic

.

ONLY

in

and

pipe

in

tli<

e

as sbown in Figut.

Figure

relief

j·

r

'

pipi.ng

ns..

in

ait

as

install the

Figi,Jrt

J4> page 1

Vtor and

..

~pus·aJ

1$,

pt.~g-e-13

valve

shown

!Ur

dpatts

12.

.

ir1

th

is

-separator

4.

This

i(,o

tank

IOGition

•

Low

wa1er

A low water cutoff
radiation l

Use

low
type is rtcommended.
boiler. \"'ire contact as

cut-off, when required

dcwlc•

e-.-e

l or

by

~tain

wate

r cutoff designed for water instaJJations. Electrode probe-

If boil

er
units where they can

dling

air , u

se

pr~\rt

nt

Jation

of

damage

personal injury. dearh or substantial property damage.

is required when boil

stat~

or local codes or

Pur

chase and i

.shown

i.s

connected

in

Figur~

nstall

in tee in supply

67. page 56.

to

heating roil

be

fl

ow

control

gravity circulation during cooling cyde. Circu·

cold

r:o

the hear exchanger, causing possible

\'lllws

wat~r

through the boil

or other

Backflow prevent<!"

\"/here required by codes. install a backflow preventer in the cold

water

fill

pages. Install

Une, as

t2

a c.

shown

beck

\'alve

in

s

uggested

if

a

backflow

piping

pre't<enter

er

is insralled above

i

nsuranc~

s located in air han-

exposed

companies.

piping~

to

refrigerated

automatic

er coul

d r

diagram

s on fo

is not installed

mean

esuJt

seveTe

llowing

s to

in

Legend

)atlo.-t plug

lng.

2

fad<tls

i.n

gtb.:c:au.~racl

$ius.

alt.

proVIded

-C/J\'<r

fclr

unused rcllef V'

1

jad:et

the

unu>«i optnln

rn:rvtclt<L

3 Boil

4

5

6 Connect

er

relid' \'liiV< (from ll«c$$Ory bag)

'4"

x 3

••

nippl~.

provided in

~··

fditf

vah't tapping in back

\'31\'C,

min1mw'n1i,.

S..

flgur•1

oli\'

t

Jackt

W!U

r t

W6

re

lief

valVe

$'iU:

i

ti,I;Sed

for two bOtltr

.g

Wid>

acccssory-bag

.$b:ti<>n

c,l.ilicharg'e

3,

pogoo

r..art

plp.

ing

13

.

nwuber SSO-l42-7iU/IOil

.....

"~"''"'

op6i-

the

plug

to

rdid'

GV90+ Series

2

OAS·FIRED

WATER BOILER -

Boiler

Manual

Install

Figure

13 Relief valve installation guidelines

IAwARNIN61

To avoid

du•

per

Discharge line
ro rtli

safe place

discharge li

p~•ttn

or proptrty

disdlarge.

Dischar

po

\~vt

out its entire l

Discharge
f'rom

6'

discharge

The

plai
rial

37

Do not

place where

No
betweton r.he relief valw and boiler.
or in the discharge line. Do n
plug or pl
discharge line.

fur

filling and pressurizing

l

disdlarges flffly. If !he

Opt­ne-w

Failure
guidelin
r.ht­in possib

jury, dear.h

da.mage.

water

w.-rd•m•ge

to relief VIIYe

loc•l

or st.te

ef

valve

of

disposaL Terminate the

nt

t

possibiliry

damage should r.he

ge

line

ssible

and

discharge connecti

line must pitch downward

the

valve

above

the

will

discharge line shall terminate

n,

nor thread

se

rviceable for temperatur

5°F

Or grt:ater.

pi

pt

(reezing could occur.

shuroft' valve sha

ace

the operati

ift

ing r.he le•;er. Make sure r.he

piping

or

op•mlon,

codM-

:

must

be

con

outlet

and

in a manner

of severt bums

must

be

as

be r.he

same sir.e

on r.hrough-

engr.

h.

and tenninart

floor

drain

bt

dearly

vis

ed,

with a mare-

the discharge ro

ll

be

any obstruction in the

on

or r.he \'al

vah'f fail

rate corr

rf'lief vah·

rf'liei'

ectly,

repl

ace

e.

to

comply with

es could resu

\•alw

ili

ty

of

or subsrantial property

lt

in failure or

to

optnate. resultin

se\·e:re person

acalclng

nected

run ro a

that

\'ll]vt

short

as

at least

where

ibl

e.

es

insralled

ve

after

system

valve

it with a

r.he

above

al

• •

will

as

the

any

o(

any

ot

by

s to

g

in-

(continued)

E

xpansion tank

Figure 14. page 14 and Figure 15. page 14 show typical insrallation
expansion tank. Al
shown in r.he suggested piping drawings. beginning wi

Ensure r.hat the expanslon tank

volume

ngs for detai

i

handle

in

and temperatu-re.

th

e expansion. These

r.

he system pipin

Diaphragm·

Refer

ro Figure

or

bladder-type

NOnCE

ll

an

Insta

manufacturtr

automatk

way$

locate r.he air separator and expansion tank

size

w

iJI

handle boil

Set'

tank manufacturer's instructions and rat-

ls.

Add

iri

onal ta

nks

may

be

added to the

ranks may

g.

UndeniZCid

from

th

the

fiU\•ah-e.

th

ecokt

locate this elsewhere in the system.

or

blaclcler-type tank:

14

,

page

expansion tanks cause system

e r.tli

ef

\'lllve

E\'entual

water

flllconntcUon at the expansion tank.

·14 for suggest

be

installed

and makeup water to

section

fallucecan

ed

piping when using a diaphragm-

expansion tank.

Diaphragm·

flU

prNSU'e

pressure
to

be

sure r

PSI G.

Operating pressure

sion abo\

avo

id weeping of relief vah·e.

's

instructions.

o.-

wi

a~nd

char

e:ad

ing

-e

cold

air

wnt

bladdor·typt expansion tank- Control

th th

e rank air char

ge

tank

with

tank

is

accurate. Boiler reli

of

fill

on

pressure

system. after temperaturt

, should not

top

of the air separator, per separator

th

Figure 17, page

er and system water

sysrem

by connecting

be

resul

ge

pressure. Always ched::

removed

ef

\oalve

exceed

Closed-type expansion tank:

Figure IS, page 14 shows suggested piping
sion tank, in which the air is dirtctly in contact with rank

Connect piping

fitting.

Slope

hori1..0nra
Always

(
a>'oids

heighr in the tank.

shown

NO

TICE

use a

). The

air bubbling

(Y:t,.

or ·W') from

any

horizontal

l pipe.

tank

fitting. such

fittlng

reduc
the

COI'I"eCt
air ro escape from the system and

of

th

e tank. This will

rdiefval
NEVER

dosed-type-expansion rank. The air

will

Cl~type

instructio-ns for

for

normal level and system water
va

t

ern

excttd

v.e

use

cause water-l

appr<>Ximately

lw

i.s

se

peca

ture expansion

24 PSIG

piping a minimum

as the

es grav

ity

<>Ugh

the

tank wate

aU

leaks in

due ro over-prtssuri:zarion.

an

automatic a

oggi

expansion tank-

ftUk'lg

12

·t for 30

PSJG.

to

a\ro

when

usingadosed-typeexpan-

the

air separaror t

of t

B&G

Tnnk-trol or Taco

flo

w of wate

the

system

result in water loss

ir

ng

of

the

PSIG

Operating pressu

abo\'e

id wetping

r In

r, and

provides

or

tank piping.
will

venr

in asysttm equipped wi

~moved

the expansion tank.

Follow

tank. Typical tank

when

the

i.s

co

ld. Note that boiler relitf

cold

fill

of

reli

op

outlet ro r.he tank

inch

the

plplng

cause water-logging

r.hrough the boiler

tank

tank

re

presSW"e

ef

vahre.

of

the

as

16.

if needed ro

r.o

tees

ware

r robe l

os

added through

t.

Always

locate

Never

from

sy.tem

is

ser for 30

expan

24

PSIG

to

warer.

per 5 feet of

Taco-Tro

to the

tank,

the

proper

fill

le:aks

alloo.v-

th

from rhesystem

man

ufac[Uru's

si'z:

ing provides

is

fill

ed to

the

of

sysrem. after

, should

not

t

-

l

a

Part num

ber 550-

14-2

-783/10 12

13

GV90+

Series

2

OAs-t'IRED

WATER BOILER -

Boil

er ManuaJ

Install

Figure

14

Pip

bladdllf•lype

1" N

water

ing to single-zone system using diaphr

expansio

PT (su

ppty from

piping

n tank.

1"tee, return to 1

Boiloc conn

(cononuedJ

"'

recuperator

®

t

agm

ectio

· or

ns

are

Figur

e 15 Pi

ping

closed-type expansion

lan

k

Pipe

NOnCE

NO

nCE

diaphragm-or

tom

of

the

Pipe dosed-

separator.

type

theairseparat

tank IOC'<ltion, as shown abc

1

Rtli

ef

vah·e discharge piping-

2

Isolation

3 F

iJI

4 Di

s

how

5 Air separator

t4

\<al\'d

valve

aphragm-type

n in the suggesttd pipi

provide with
with

diaphrngm

pi

pe air oudet to

dOS<-I)'pe

UUlk.s

bladder·l)'peexp

(air

in

contact with

or.

Alv.a

ys

connect

we and

stt- page t 2

txpanston

automatic air wnr ONLY

-typt expansion

expans

tank-

ng

drawings

ion

rank

ansion rank.s

water)

the

fill

line

in

the

al

ways

in this

when

ranks

when used

to

tank.s

to

to

the

ex

suggested

Legend

locate

as

manual

used

wi

th

the

bo

t·

the

top of

pan

sion

piping

l

8 Cold

7 S'r•l=

8 $ys\o:m

10 PfclsWe

11

12.

13 Tank fittlng

Jill

line.With

wb,..

rtquited

pi\lll'lit

~)

.u~plyp

n;wro

i'edllcing valVe

Quk-k>Jill

C

IU<M-

i

ll

the

b)'lll>ss

cyl"'

:~

ugg

esctd

.bac~owpteventerilr

by

c<ld•• t<et Figute

iuin

piping

valve, wbel) u

E'ltj>I'>Ml6o

piphl8

$

wh.m

1

ranlt-

d.rawiqp

15

USc~

sed

alw

oys

iu

thi5

Ch

eck valve

foi

typioil cOm-

!o.:a~e

o.<

Slwwu

manua

l

GV90+ Series

2 OAS·FIRED WATER BOILER -

Boiler

Manual

Install

Syste m

NOTICE

Ci

rculato

IAWARNING

Circulator flow

Size
r.

he temperature change needtd.
perature rise
formula, where
rate (in gpm). and

I

system c.irculators based

water

wa

te r piping me

Most piping
primary/seco n

These

GV90+ boiler , for the
oprration

For othe

McLain r

rs

Do

no

for

u.st elsewhere in

rtqu-irtd

w

ill

cause the

pr

operty

Ntver

GV90+

erarioon

damage

Failure
maJKe
flo

w.

(o r

drop

TD

BTUH

methods

dary

designs

of

the boiler

r piping

tprtktltath

t remove either

for pr

ope

boiler

damage

Install

another

bollcw. Forced

of

rhe boiler controls. Substantial pr

could

rtsult.

to

comply coul

and

nuisance shutdowns from insuffident

rate

on

} throu

is

temperature rue (o r drop),

is the hear load

FLOW =

Examplu

Consi
to

210,000

piping

:

der a sys

Btuh. Tbe

is

20'F.

tem loop for a system with

desir<d

temperature

Then

the required

210,000

FLOW =

20x

SIMPUREO:

Circulator

Th

e circulator
against the head Loss that
r.

he pipe si
engineering
ro residential systems.
units

or

I

AcAumN

For

20"

IOJTC)oraturo

head

te

needed and r.he resultant head loss using accepted

method

radia

nt
The following sim

I

cuJaror

tionsusingbaseboard (finned

r
heati ng.

requirement

mUISt

be

s. The slmp

and does n

tub

ing.

si:z:

adiatOrS

f.m

capable of delivering the

will

ing must

or

COn\rtctors.

coil uni

piping

thod

shown

con

ensure proper flow through the

methods>

•e.

of

the

r operation. Remo\•ing a

to

cou

ld result.

flow

d result

the

flow

You

gh

a circuit by using rhe foll

in th

necti

on

to

mo

st

effkient

and Lhe

consult your local Well-

the

GV90+ intern

system. Both

malfunction. Subsrantial

pump

In

can

cause

in unre-liab

rate required

can closely estimate

fo

r the circuit:

(continued)

s

i.s

manual u.se

the boil

and

heating

pumps

..

-.

improper

to

FLOW u flo

er l

oop

reliable

syst

em.

al

pumps

pump

wtth

ope-

le

~rfo

ac.b..ieve

tem

owi

art

the

op-

rry

r

ng

w

BTUH

TD

X 600

rot:al

heating load equal

drop

through the system

flow

rate

is:

21

600

occur

llfied

ot

pUfied

be limited ro residential applica

rs

=

drop,

FLOW • MBH

in

the piping. Dt-termi

pipe

~z.ing

include systems with

method for pipe

or

DO NOT apply for radtant

or commercial installations.

gpm

/10.

required

here is limited

cast iron), cast iron

fan

and

flow

ne

coil

cir-

Simplifie d

t.

lnsrall r.hr boiler and piping usi

.

-

-

layou

2.

Site r.he

heating system

head

a. Dettrmi

b. Calc.ulate the

To
MBH (I

Exampl
Btuh:

c.

Find the pipe site in Figure I 6 that has a

just larger than thar

d. Find

TEL
using the equivalent length

the same head

length of the circuit

TEL

circuit for residential baseboard, radiator
t

e.

Measure-r.he ltngth

oudet

1

f. Find r.he head loss for each circuit:

g.

NOTE.:
aU connected

3.

Example:

a.

Fo

MBH).
b. Flow= 45 MBH / 10 = 4.5 gpm.
c.

TEL=

d. From Figure 16, seifct I" pipe (max

e. Head loss = T
f. Selecr a circu l

head

NOnCE

Figure 16 Flow ra t

Pipe

size

(lnctoas)

~

1 8

1

14

11\

pip

e/c

ircul

rs

in

r.his

manual.

pip

ing and compontn

usi

ng

Figure-

1

IOOoSin

or

..5

all

piping

wtll

nt

r.he

heating load (Btuh) for each circuit.

flow

rate f

use a

200F

temperatu

,OOO's

ofBt

uh) by 10.

e-Flow for 20'F temp dr

FLOW=

r.

he

t:Otal

accounts

Is

usually_

35

required for the circuit.

equh

·alentlengr.h

for

losse

loss.

Add

to

close to

applicstions.

of

bsdc

to irs

inl

et. Then muldpl)• this length

to

ger

tht

approximate

TEL • 1.5

H

EAO •

X Circuit

TEL

X 0.04 (feet

Siu

sy

stem """der piping for the total

or

re

MBH I 10

s through 6ttin(!'

tllese numbers ro rhe

find

each circuit from rhe circulator

Length

z.ones.

r a circuir with heating l

Measur<d

1.

5 x 88

of

5.28

To use this method, limit the

finned-tube baseboard
board

the c.

of
into

<:Opper pi

MAX--

• 0

.04

I

length

feet = 132

EL

x 0.04 =

ato

r that can deliver ar least 4.5 gpm at a

fee

L (Read the NOTICE below.)

and

limit

irc.uit

cwo

or mort .

es

...

4 2 45

14 3 140

22

flo

requires more

tor

0.04

pe

(based

(G

Pt.l)

per

loot

ator sel

ng

the recommended piping

rs

for each circuit in rhe space

6.

At

the

bo 0.041oot

each

drc.uit using its

drop, just divide rhe

of

TEL

1.5

times the length

TEL

of

wate<

oad=

of circuit

fe.t.

132

x 0.04 = 5.28 fe.t.

to

3.9 gpm,or

w to 7.1 gpm.

fMt

hfHid Joss,.,-foot of

oo

water

Pipe

size

(l

nctoas)

:lli

•

ect

flow

rates lsted,

per

op

with 35,000

= 3.5 gpm

(TE

L)

oftht

pipe

r.hat

in

feet

.

the circuit.

(feet)

column)

45,000 Btuh

is

88

fffi.

flo

w= 8 gpm).

flow

If

flow

, split the drc.uit

at 140"F)

MAX--

• 0

ion

foot

of

max

flow

circuit.

and

valv es

would cause

measu~d

or

convec·

tbrou3:h l4"

use

the total load

.04

...

per

75

290

the

piP<>-

load

rate

by

of

the

times

flow

of

(=

45

I base-

(G

Pt.l)

loot

Part num

ber 550-

1+2-783/1012

15

GV90+

Series

2

o.Ali-FIIIW

WATia

IIOILER -

Boiler

Manual

Install

Figure 18

, ··-··- --··-

I

1

r---

\

...

1-,

'

I

'

I

Zqn~

(DO NOT apply

~

-"-

water

vallle

zoni

L

---

--

®~

Zone 3

·

L

Zone 2 1

L

Zo

~

piping

ng -

GV90

+3, GV90+4

to

GV90

+6)

(ZiY

10 3U•t•u

li

~

.liVI

h

l

- - " - •· - ·• - •·

----

~

----

lZCfle

2

Clrctl

!l

P-!Vlfll -

~Zona1o-rWfl~&ml

ne

1

_ .. -

(contrnued)

or

GV90 +5

~

..

-

'"l -...

..

- .. - ·· ._,

- • • I

-------------4

....

..

_,- ·-

ff_t

'

'

I

~

I

..

i

I

I

I Isolation 'ildvet

Aolomalk

2

di

aphr~m-typt ~n

lion u ). or conn«:t

ta.nk

ex;

DUpbra&m·

ty~

'

uud.

~ion

to~p

u:nk fiu.ins u in Fi

UJ'It

Boll or

GV90+3
GV90+4

GV90+5

air

'lftlt

6tuog (doted-rype

pantion tank). 10

or

af:n

( r

of

15

, f!t8t 14.)

Pipe

model

bbddtr-

sion tllnk,

dosed·typt

tl.nk.pipefrom

a.tr

upua

sizes

tor to

Legend

Zonewlft

(with

•

7

Hose

-

10

if

16 Cold

s·

(NPT),

Mains Circuits

1'

1l4'

bibb

8

Boile

r

prtsswt/~tmptn.·

"""8'"8'

Difft:rentia

putva

lw

watet

Fisure IS, page U for

typicd componen

minimum

pu.rse

l

pttsswt

fi.D

line-

14'

14'

va

lw

br·

8t'lt'!

tt

I

•

I •.:fl

: :

'

~

-

!_

--

-

-

--~

~

F

1

f

Figure 19

Bo<ief

mode

t3V90+3

GV90+4

1hesyslam

Ql

rculalor HEAD

l avallabls

S\'SlO<Il

e,

.o

~eot

0 6.SGPM

4-

.1 feet w.

Ill 9.7GPM

-

---

m

~

10

the clr

""

"'

c.

meet lhe tollowing r

Maldmum

cutt

longll\

L

103 lt!el

92feo

'M1nlmum

number of any of

oto

l 3

equ

irem6f"lts

lrcults circuit

when

load

40MBH

33MB

NOTICE

applyin~;~

Max

(0

H

Circuit

One-p

plication information

on two-

\vhethe:r the internal circuJaror
suff'ic
sys

rem> use

Figure 19, page 17.

Figure 18

f&el baseboard Summary

any

circuit

600

BWMoot)

67

feel (max 4 GPM any circuli)

55

feel (max

requirements

See

Flgure19

lpo

<1

- - systoms

pipe

baseboard

ient

flow

the a\'llilable head value given in

to a one

6.5 GPM

20'F

9.

3.3

on

this

sys

tems.

-pipe div

1018

7 GPM

1018

GPM any clrcuh)

-T

page

can

1

1

he

is

based

To

check

provide

erter

ap

tee

-

5.5

,

QV9(H.S•

f,ln

number S50-l4:l-783/ l 011

loti! "'""

08.7GPM

f1~lilat

3 53 MBH

eo

feel (max

30'F

6.7GPM

3.5

GPM any circuit)

drop

17

GV90+

Series

2

oAs·FIRED

WATER

BOILER

-

BaUer

Manual

Install

Sin

gle

-zo

Rad i

anr

heating

system supply
water temperarure

ing conditions.
supply water temperature

Figure

22

uses

rtmperaturt.

the suppt) • temperature limit control (irtm 14)
sys

tem from over-temperature conditions. Nore also that this piping

requires a separate system circulator,

fl

ow rat

es

of radlant and beat pump

Manual adjustment

zone systems because multi-zone sysrems
making it unlikely an acceprable
Figure

23,

page

You

may also apply the suggested piping

Fig

ure

24,

page

or outd

oor

reset

water

ne

rad

'-11 healing or

sys

tems

and

war:er

temperatures below

will

be

at least I

So

the piping must indude a method

to

rhe system.

two

'balancing val

Follow

the instructions

piping

heat

pump

SOOF

ves

lO

manually adjust

~low

as

system

of

the supply

20

or Figure

20

if

you wanr auromatic suppl

remptraturt

temperat

valve

24,

page 20 for multi-

contro

l.

(continued)

heal pump

systems usuaHy require.

1400F.

But

the boiler

to

1600F

dur

ing most opt.rot-

of

r

Mudng

rht

supply Wiiltr-

to adjust these valvts. huuU

as

shown to protect tht-

shown>

because

of

the hjgh

s.

u

~

is limited

will

cause

setting could

1.o

of

eir.her Figu

)•

temptralure regulation

to

varying !

be

found.

ne systems.

re

23>

page 20 or-

Ol,it.leL

the-

n-

single-

(load$.,

See-

Figure

22 Sin

h

jo

g!e.·zo

eat

na

PUII\P

"'

radi~t

heating

systom

"

01/90+

ot'

or

a

""'

.,-,

For additional information and altemativts in piping for radiant
ingsystems> con

J

/IOTIC

E 1 Tho system circulator

Adju

st

Use

\•alves

water, reducing su.pply

I. Subrract the design

rhis

number rbe temperature

2. Open val

3. Starr the

4. Let the sysrem warm up

5.

Note

(boiler supply).

6.

Slow

ly

tower th

in

~t<p

1. Example:

ture dtfferenc.e

until gauge 9 reads at least

tad.

\Veil-Mcla

stall«.

bal

anc

ing valv

17

and. 18

to

ware

system

v<

17 and

boiler and

the temper

dose

an

gauge 8 by ar least the

I.

Fo

do,.

system.

atu

re ar gauge 9 (sysrem supply) and gauge 8

\-alve

17 while opening

r a desi

gn

woUld

in.

,...,t

bo

supplied

es

mix boiler supply water with

r temperarure ro the sysrem.

supply rempe:rature from 1

va

l\·< 18

f'o

r about

supply

be

I

SOOF

SOOF

dtffennce

.

temperature

temperatu~

minus

lower than gauge 8.

15

minutes.

\•alvt

IOOOF

.

18 unr

of

1 00°f,

. or

dtfferenc•

SOOF. Set the

by

sys

tem return

50°F. CaU

ll

gauge 9

r.

he tempera-

hc:a

tho

In·

1't'"Jd

fOund

vn.J\ftl

t-

"'""

Lege11d

1 Isolation

2 A·utomaric air vrnt twilh

tank.),

s.ioncank

3

~i.ap.h.rayn·

(F'ordasti!·t)~expan·

sep~.mtort

5 S)?tt:m cirtu:b.tor

7 H

!

fl

IRHierr

~

Systt:m

10

R~tu.rn.

14

~

Upplyfempt:ramr~

tu

directed by the-n•stt m

16 Col

compa.n~nn

17

Ril..l

T&h'el.

or

oonnec

uo

diapfU'BJPll

tank ,fitting

l~

or

bl

adthec-typ

o

tarik 6ttingasiittf.lgurt

nSt" bibb

rtbtklw th¢

purg.e:Ya.h-e

~e(te:mpc-rarure

supPl~

terupen1twl! g:.uge

rem

pt:rof\l.fepu~

max

imum

dwar;er 6Uline-

ando_g

vai"Vt>.

t:

sion

tank.

gauge-

Umitconttoi-Sd:'!lt'9

'Ill~

Wig:ner

seef

igure

·fl'F't

d-type .

p¢

fm.rn

15~

the

apauSioll

e:xpa

t¢k

i.

(l.!Sed

1

topofilir

pagt 14.)

U!mpe:ra-

'Ylll<!'m

forrypfca

or Ill

(dose

exF*~.Oo

pi

for

.

ts~pagelA

n·

I

l

Part

number

550-1+2-783/1012

'!

S.l""""g""'="'

!:.----------.!

19

GV90+

Series

2

oAs·FIRED

WATER

BOILER

-

Boiler

ManuaJ

Install

Multi-zone

Mu

lti-zone systems require

ply

temperature

(zone-

\-alve

piping for these sysrtms.

I

AWARNJfG

Zone-valve

for

heating S)'Sttms and
system

Circul

remo,red. Provide a

I

NOTICE

NOTICE

NOTICE

I Provide an automat

sys

tem

whe

.aror zoning - The

water

radiant

becau.se

roning)

zoning-

circulation to

n

and

moto

r-Optr.ued val

desired

protect the radi

supp

The

to

the

rttu

rn water temperature

separat~

Baianc

lr).g,

val\·~

for one

the memory-stop v

isolarion_

Zoning wtth

transf

orme

former

zone

Do

to

vahres.

not

LIM R & C

piping

heating

auromatic regulation

of

wi

dely

varying

Figure 24 ( circularor zoning) show suggestfil

ic

ve

l)• water t

sugge

provide

assure good temperature

GV90+

circul

when

of

zon•

r to power the zone

hand

Alternath<ely,

tmptratu

ant

system from

sted piping uses a separate circulatot

the

internal circulatorS must n

atO

*"'lnKI

the

isolation

ah-e

valves- Provide a separate 24-voiL

le

the

total

coi'WMtCdons

system

load conditions.

temperature control valve

\vhich can

rt . This is required tn

excessive

hlgh

er

flow

is

l

ow.

r for each

- Substitute a memory-stop

valves

for

balanc.ing

valves.

rated

use

a 20ne

for

rconunuedJ

of

the

be

adjusred

temperarure.

typical

di.srri

buri

7.0

n ~

.

in each

flow

Size the trans-

load

of all

valve

20ne

zone valvt.

syst~m

Figure

for the

of

radian

on

in

ot

z.one

ro usc

as

well

conne.:

controller

sup-

the-

ted

2.3

or

be-

as

t

.

Figure

...

I

0

23

A~to

system

zooo

valva

~-.].

:~

-

•. zonol

-

Zon•"

c:>

1

"'

-·

0

"

'

t

Q

"'1PPiY

ZOflt

ng

--~-

<::I

¢1

•t_t\t

'!\

~ ~

~

.

temp regulation-

~

1'

••

r;o.

~·

'll

OV90

._

I

"t

I

Q

19..)

0

...

NOTIC

Outdoor

App

ly Figure

of

the supply water remperaturt.

and

an outdoor reset temperature control

Zoning wtth

E

circulatOT
one

from

boile
circulatOT

tem clrculalor

reset

23or

of

th e factory to

r.

Figure

circulaton

cann

ot

be

tbe zone circuJarors. lr must remain as shipp

You will

rela

ys

24

for any

n

~

or circul

must

Legend

Lsolatfon vatves

2 Automatic

connect to

3 Diaphragm-

type expansion

as

in

4

Zone

5

System

6 Flowlch

7 Hose bibb purge

8 Boiler pressurelt

9

System

10

Supply tempera tore

I I Differential presswe by-pass vatve

16

COld

air

vent (with

tank

or

bladder.rype

l~pa~

or

zone

eck

val

supply t

tanlr.

ci.rcuJato

ve

emperature

Figure

val\>e

,ater6Uline

6tting

vah-e

emperarure

- see

diaphragm-type

(

dosoecf-type

pipefromtopofairseparatortotank

14

.)

r

auto

matic mixing

Figure

- The GV90+ internal

removed from rhe boil

allow proper flow

a circularor for

ato

r zone controller.

be

supplltd

system

inrended forourdoor rtsel

Use

a motor-operated three-way vah

sy

expansion

expansion t

gauge

gauge

l~page

ank.

vaJ,-e

14fortyptcalcomponents

~ach

by

stem.

expansion

tank

if

used (

contr

ol

zone.

the

Installer.

tank)~

),

For

er

for

ins

The

closed-

fitting

sysrern

use

as

ed

ide

the

Provide

sys-

re-

or

Figure

...

I

0

ll

24 Auto system supply temp reguiat

ci

rculator zoning

ZOn.G

Q

2

~

"'

-

~

-

+

~

-

.,.

_

.,.

Zona 1

t,!::

r

\I

--

£:>

¢3

:f#

-

~:

@{

ri

•

GV90•

I

·

~

(?o

X

·~.

<::1

T

!~

iQO

·

~

951)1

-

..

I

0

Bb

20

Pan num

ber

5SO.I<t2-783110l2

GV90+

Series

2

oAs·FIRED

WATER

BOILER

-

BaUer

Manu

al

Install

Pipi

ng

snow

snow

Combination snow mdr/space hearing sysrems can have

temp

these systems
Figu

Select

which

60'F.

Zone-valve

fo

system

Circulato r zoning - The GV90+ internal circulators must

r

emoved.

melt/space

erature

re

25

(zone-\tal

an

automatic

can

bt

Any

S<tt

zoning-The

r sysrtm circulati

when the

Pro\ride

NOTICE

NO

TICE

water

melt

bel

ow

60'F,

~u.lre

ad

ing higher than 60'F

The retu

ar Jeasr
r

control operation

property damage.

Zoning
d
on each

these

for balancing

Do

automaric rerum water temperature as shown

ve

tempera[U~

justed tO pr

on

r

~turn

:a

St-parate

WF.

erur.n

ttmptrarurt. Fail

with

iagrams

side

in

each zone

not

use

systems

he

and

the

7.0ning) or Fi

O\'ide

suggest~

to

assure

good

water temperature is low.

circulator for

r-n

warer

Provide

problem

zone valves -

in this

section is

.

Substitu

in order

flow

R & C connections for

piping

or

combination

ati

ng

systems

return temperarure w

gu

re

26

(circuJaror

control

\'ll]vt

or motor-optTattd

a rerum water

will

also

pip

temptrat

ttmptrarure

and

urt

te a memory·stop val

as

well

as isolation.

rtmptraturt

be

acceptable.

ing

u.ses

ure

each

zone.

ro

apply

means

to do

so

s,

caus

ing

Each zone in the piping

shown wi

to

use

the

a separate circuhnol'

distr

the boiler must

can r
possible signifi

th

memory-~top

zone

(cootinu

rttu

ill

flu

7.0ning).

ibution in

to

regu

esu

an

iso

ve

vatve.

ctuat

of

lt

lation

for

edJ

rn

wafer:

e.

val

at

least

nllt

late the

in

boiltt

cant

valve

O'De

vah-e

So

in

~

l.hf

be-

bt

of

Figure

26

Aulo r

zoning

<::1

-1

•!

)ltC":i

r::::>

;;-

s

e\Um

temp regulation- circu lator

---

··==

Hcn

tingzono<&

C3

..

......r.

~

·1

I

•t-

--1

:

~

......

6

J)

"'

~

r

(j

..

£l

-·

--

:

~

<::3

_A

~·

·

~

·

~

=''1

fl

\\I

Pro

vjde a

separate
valves. Size
of

all

NO

TICE

I Isolation

2 AutomatK

3 Diaph

4

5 System or

6 Flow/check valve

7 Hose bibb

8 Boiler pressure/temperature

9 System suppty temperature

10 Retu

II

16 ColdwatertiJlline-

Zonl
circuJator cannot
one

from the

bo

iler.

circuJator rdays

tern circulator

vah>es

connect

type expansion tank, pipe &om top

as
Zo

Differential pressure by-pass

to

ragm-or

in

Figure

nevalve

rn

temperat

tone

p-urge ,.aJ

the transformer to

connected zone val

ng wtth elre!Jators- The

of

the

z.one

fa

ctory to allow

You

will

air

vent (with diaphragm-type expansion tan

tank fitting (

bladde

r.t

1

5,page 14.

circulator

,-e

ure a

ut

we

24~\·ol

t

transformer

han

ves.

be

removed

circulators.

n

eed

a circulator for

or ci

rcu

I'MIIt

bt

from

It

must remain

proper

lator

7.0

supplkld

Legend

dosed-type

ype expansion

)

omatic mixing valve

Figure I

gau~

gau~

vah-e

S,

page

expansion tank),

tank,.

of

air

separat

14 for typical

to

power

the

dle the

tota

l rat

ed

GV90+

ne controller. The

the

flow

by

if

internal

boiler

control

each

the

used

(For dosed·

or

to

com

system

fo

r

as shipped

in~d

7.0ne.

Provide

Installer.

k),

tank

fitting

ponents

zone

load

use

e

sy

or

as

the

..

Figure

26

Auto r

e\Um

zoning

S•\owmclt

M&texeM.ngor

F1

"

~

t

r::::>

",

-----

·f

C3

Haating tonels)

C3

• 1l' ..

·~·

u. Q

''L

temp regulation-

~

; .

.,

~·

OVH•

zono;

C1

((I\

valve

Part num

ber 550-

14-2

-783/10 12

2J

GV90+ Series

2

oAs·FIRED

WATER

BOILER

-

Boiler

ManuaJ

Install

Wat

er chiller

Pi

pe

the boil

Install boiler, as
heating boiler.

Use

appropriate

See

Figur<

Install the

Figure
If boiler

th ey

can

automatic

NOnCE

NOnCE

NOnCE

er and

27 for

flow

27)

to

prevenr gravity circulation duri

is

con

nected

be

exposed

mellllS

Balancing, when

\'lllve for one

the

isolati

Zoning
transformer to
forme.r to handle

zo

Do

water

system s

wa

ter ch

shown>

\•atves

typ

/c.

bec

ne

not

so chilled medium

to

prto\'f

ical i

nstallAtion

.k

''31

to

heating coiJ

to

refrigerated

ro

pr.e\re

memory-stop

on.

wtth

vahoes.

u:se

piping

ill

er

as

shown in Figure 2?.

nt chilled

'" in

the

nt gra\rity

111qulrad

of

the isolation

zone valves -

power

the

Alte.rnati,-eJy,

R & C eonnecUons

medium

of

balanci

boiler

supply

s located in air handling uni

air

,

use

flo

circulati

- Subsriture a memor

valves

\'alve

for balandng flow as

Provide

the

zone

total rated l

use a zone

rco

nun

is

piped in

ng vah"

ng

the cooling

w c-Ontrol

on during cooling

from

entering boil

and

piping,

in

each

parall

check

as

shown in
cycle.

\..Uve.s

1.0

ts

or other

ne

a separate 24-volt

valves.

Size

the

oad

of a

ll

connected

valve

zone

ron troller.

for

zone vatve.

uedJ

el

with

er.

vruvt>

where

cycle.

y-sro

p

to

us

~

well

as

trans

~

Figure 27 Installing

water

clii

'7

~

.

0

•

Q

~

GV90+

ll~K

boiler

@

e::>

il

in

syslam

~

~

rJj

(!)

with

4ij

Q

NOTICE

Zoning with circulators- The

circulator cannot
one

of

the

from

the facto

boiler.

Yo-u

circulator relays or circulator zone controller.
Chilled water

as s

ts

how

()n rh

ranks,

air ven

be

removed from the boil

z.one

circul

atorS. It

ry

to

allow

will

need a circuJator for each

systems

n in

ese

ofren use dosed-type expansion

Figure

systems.

proper

27.

00

GV90+

must

flow

NOT

internal

rtma

in as shipped

control

z.o

insta

er for use as

ll

system

inside

ne.

PrO\ride

automatic

the

asou

Legend

Lsolatlon

2 Air separat

3

E.xp&Mion

application of a closed-type expansion tank)

5

System

6

Fl

8

Boi

16 Coldwater

components

17 Balancing val
19 OliU

20

Strainer

21 Oleck

22

System

23

System

vatves

or

tank with tank fitting (piping shown for

circulator

owlcbe

ck

valve

ler pressureltemperat

6Uline- see Figure 15,page 14 f

\>e

er

valve

supply

return

we

gauge

or

typ

ical

22

Pan num

ber

550-142-783/10

12

GV90+

Series

2

fl4!i"f'Ot£u WA711'1

••~•1-ER

-

Boiler

Manua

l

Multiple

Placing

L

Loco

multiple

te mu

ltiple

boiler

bulit'n

to:

a.

Fig:u,rc.-28

b.

ngi!Tt

2.

Pnwidt

li.sttd

ab<>vt:

thdt

-r~mmuded

(

.)J'Ov

ide ut l

_givm

on

3.

Construct

ls

un

even

fOundatiOn

mem.lons

4. Cbatklioe boiJ

:r

oom

flo

$. Uoo'a(e, i!il:c:mbleand

instrucfior

6.

Pi'O\>

idc tll."aiance

piping,

r('r'

and

(s\1.1.:-rb-side

29

(baok-t<rbock).

the

de:arancd

to

pn>vid.~

t9St

th~

rt<:O

vase:

..s

.

A.I.Mf

boiler foundation

or

if

there ls a danger of

tO

allow

dlown

in

ft

IOCiltl

oc.

t.s

in

dlil

m11.uuat

fot

gas

pipi

ng_.

~pansion

(tt.hC:r

ac~rits.

the

installations

bolters

in

baiid

iOom accur

j,

or

indicated io

furaccw-

dim~siuo

rnt

nt'lt

fbllow

for clearance and

iUUStnJboo.~

l'm.~

on

mount

in.n:allat:ie)

the-Ul

~trations

tu.H

l

se-rvicing.

s

an:-

nOt

de-d

~ct

cl

local

oodrt.

if

bo

iler

room floor

flooding.

$pacif)g

Ol tight

f:Pu

udatiuu (lT boil

bOilers n«""rding

n or

YC'.rt~og

tank, primary

d.iug

If

:po~ihle,

e-a:rances.

S

ize

di-

.

eT

Ill

,

,

ait

drcul>l

-

Figure

--

Figure

28 Side-to-side

sh

owing

FifGOMME:NOED

w

------

29 Back·l

sh

owing

<>bad<

RECOMMENDED

mounti

~

61

" _

inslallalion

ol multiple GV90+ boilers.

clearanc

___,

___ ••·

es

--

•

o1

muniple GV90+ baii

clearances

O<s

f

)6

,

'

Controlling

multiple GV90

bolters

I. Multiple GV90+ boi

boiler contr
iso

lated con

bo

iler's T-T

Piping

I.

Set'

Contacr

not

cov~red.

2.

Always
primary/secondary circuit
in

this

oVseque

tact

termi

multllple

suggested

Weii-

pipe

tbe

manuaL

for ca

pipi

Mclain for

+

ler>

01

n

be

con

~rolled

ncing

syst~m

tha

t provides

ll

fo

r hear (connected

nal

s).

GV90+

ng diagr

boilers on a secondary

as

bolters

ams

in

this

assistance for systems

shown in the

us

ing any

to

the

manual.

loop

in a

txamp

an

les

1

...

J

~

!

'

-~··_..

_

__

.,.

--

•

-

u·-

I

~

--

" '

--

-:n

••

·

--

Part num

ber 550-

1+2-783/1012

23

GV90+

Series

2

oAs·FIRED

WATER

BOILER-

BaiiM ManuaJ

Multiple

Easy-Fit® plpl

1.

Main heade r

a.

New

syst<m -See

b. Replacing boil

u,

con

si

crosses
ure

nect

for

31. Siu

boiler

ng

and

E.asy-Fit•

ers

sysrem s

Easy

-Fit• manifolds

manifol

Installati

Man

ifold pi

page I 5.

in an existi

upp

ly

ds

to

handle

water

on

pt

siting.

ng

system -

and return

as

shown in Figure 30 or

toral

Witho

lines. Install

conn

ecre<L boil

piping

ur reducing

er

as shown.

2. Provide connecti

dose as possible to the mi

a. Use

b. U

t~

se

either tees (Figure 30) or crosses (Figure 31) f

for fo

ons

in main header for Easy-Fir'

dpoint

of multi

ur or

less boil

ers>

as

in

ple boilers.

Figure

30.

man

or

more boilers.

3.

Manifo

ld pla«ment

a.

To alterna
rt•terk

in

Fig

b. Return manifold must be on the rrturn si

supp

inS'

left

the

4. Connect
return connections

fl

ow rate

5.

Provide

s

hown

on r.he suppl)• and

may

r~uire

on each boiler when isolarton vah·

6. t

nsra

ll

ply piping as shown in pipi

sucrion si

7.

t

nsra

ll

system

8. Pipi

ng

a. Figure
b. Figure

locations
limits and

c.

Figure

piping dr

d. Figure 3S,page

ing heat exchanger

te s

pacing

the

sho

u

~ 30 an.d

ly mani

fold

in

this manual show flow

. For

sys

tem flowi

manifol

from

ds auo

Easy-Fi

for s

rt-

end

and

Fig

u

~ 31.

must be on

ng

rdingl

r»

manifold

using

copper

upp

ly

long-end

rhe

supply side

left to

righ

y.

branches

or

stet-!

and return

of

the

lines to boil

manifo

de

of

the main and

lds

as showt\

of r.he main. Draw-

in

system main from right to

t,

re't-erse

pipe,si

the locatio

to

boiler supply and

ud for

the

.

a O

ow/c

.berk v

alve

in piping diagr

r-eturn

the

use

in the supply piping of

ams

in thi.s

manual.lnstalf an isolation

of

each

boil

of

indi

vidual water level

es

er

as shown. Some local

art

installed.

eac

h boiler

controls and limits

main sysrem air eliminator and primary circulator in sup-

ng

diagrams. Place expanston tank Otl

de

of

syst.em circulator as shown.

acctSSOries

reoommendation drawin

30

and Figure 31 show details

32.

page

of

typical

or.her

33.

pa$e

awmgs

25

is a schema

boile

devices

26

and

of typ

28

shows

i.s

as

shown in drawin

gs.

gs:

of

Easy

-Fit• mani

tic

r pipi

piping drawi

ng

and

system

ng show

piping. including

often required by local codes.

Figure

34.

~e

27

art

r.h~-dimensionai

ical multiple boiler insraUarion.

recommended piping when

needed.

an

9. If desired, other primary/secondary piping arrangements

used.

When

NO

nCE

using isolation

may

requ-i~

pro vidi

limir for each

if omission

al

low

of the individual boiler isolation

the

we

of

limir for the entire multiple boiler

ng

boile

r. Consulr

a s

ingle water

\'ll]ves

on

a low

water conrrol

each boil

loca

level

J codes

conrrol

system.

er.

some codtS

and

add

ro

determine

valves

and

add

tees

or

Fig

ourput

ifolds

a!l

fi

't'e or

ers,

ns

of

required

as

val~

codt$"

folds.

ing r.h

iso

lat-

can

bt

iti

onal

ma)

iti

onal

Maximu.m connl!cted load

-

Figure

We

ll~

Easy-Fir"

Munllold

2..4 boll6tr.:

1

a,~anlt

5oo

8. boll

2 manifol.ds

Figure 31 IJou

t-

Cross./Dushfn

{by

olh~:~

Molh

Cap

-.

(by

ot

2·inoh

-3-

manifold-

inch manifold- 1400

4-inoh manifold- 2900

30

Single-eided

cU.ln

old

err.

I

r.l

Of'IQ

ond

g

...

~



)

..

.,

1.•

bte-s

ided EZ.fit

C.p,. (b_V athcr,f)

,-

~·

12-maxlmum

•.:

Wel

Weii-Mcl.ain

hertl

EZ~it

iot aa close

as

tac:IJta

i..Mclain

Easy

-Fit'

Manifold

Easy-Fit'

Manifold

pl!r

4SO

MBH
MBH

MBH

Head

er connection

.,

'·

1-toade<

,-(

,.

'

·"

ll

~

man®ld!

Maht

We

ii·Mclaln

Easy-Fit•

M

an~ol

~

8

bolle•s:

:tmon "rfolds

CQnnection

·.short

..

.00

l

o119

-.

ef'ld

Ma

in

d

24

l-\ln num

btr

SSG-14'1

-7llll101

'2

GV90+

Series

2

us-Fu

ltD

WA

tla 110

11.1!11

-

Boiler

Manu

al

Multiple

Figure

32 Piping schematic - typiClli f

boiler

...

.. (8'

1

·

~

VI

~

@@

®

~-

®

.....

water

or mufti pte GV90+ boilers, using We;I·

@ I

i>l.l

I

:>;

@

'

~

piping

...;(2)

>.

CD

t

-

~

~~

_L,

I

--

l;t =

\

..,

~J

J

---~

,_.

I I

(2)

)

j

--

(c()

nlinuedJ

@

@

=

Mcla

r-

I

>.

® >

'

-

in

Eas.)'

.f'

il man

ifolds

..

@)

(

3)

@

(!'

@

j

®'f®

;

'

=

~

~~

__,~-

I

r

..,.~

4

1_

,_

__)[

@

-=

Flow

/che

~

Gop

• e'"' FFi"'

p

age-

2'!1

~

Ea")'

•Fi"'

page-24

7 l!xpandoo

8

S}'J

tcml

air

JO

Pres:ru~

Legend-

ck~

~du.::in

(each

bailer

~

MntUiald

MluUfold

tank

elimi.o

----------------~------------------------~

(MJp

ply)-~J<>utaad

(,.IUlO)- by(>utaad

(dl

aphrogm

acor

g vaJ

typr)

~

sit•

I"'

ol>•per

Figure

II

Check
codes

12 Isolation

13 Watertlowswi.tch("·henused)

14

Supply water temperarure control (when used)

low

IS

16 Co

components

18 System supp

19 System return

20 (Not shown) Boiler relief

per GV90+

30

Long

32

valve

or

rbacJdlow

vaJ,-e

wa

.ter cutoff (when used) (place above primary header)

ld

water

6U

tine-

ty

Boi~

end

of

manifold

see

Manual

prevent

Figure I

valve

a:.

as required by applicable

S,

page

and

discharge

14

for

typical

piping. installed

Pan-number

ss

o..-•14:2:-783

/ lO

ll

25

GV90+

Series

2

OAs-f'IR£D

WATER

BOILER-

Boiler

Manual

Multiple

Figure

33

Pipi

ng

.

__...--

t

--......_.

(

..

boiler

layOOI

- Iypical tor multiple GV90+

water

~

-·j:

-:J

.....-·

....

..

,

-"

\

!

I

~

·

v

_ ..

"""·

~

(!)

piping

bQ

ilers, using Well-Mc

~

{

-··-··-"

•

---

11;

~

(continuooJ

lain

~

(j)

..

l

@

Easy-fit

........ ®

manijold<!

(2·boiler

t

system)

t

I Flow/

2 lliolation

3

4

5

6

7

8

9

t6 Cold

dlock

c..,.

E.uy"Fi'*

t;asy-Fi~

Primary

P~sion

Sy$tt.m

Systqm

pont:ots

valves

M>n

M-anifo1d

drculator

air

cf

automatic airvtml

water

va

lw

(I!Jllh

(""

••

.

ili>ld (supply)

(return) -

tank

(.diaphragm type)

bn

in atnr

611

Uo.e-see

21

boill!f

)

US<!d

)

-18)1JU

la}'"'

F!igur~

"32.

u

t~d-siu

Ut

and $iu

p;:~ge-

per P•8" 11

percp3ge

25

(or q'pkal

Legend-

2

~

cnm--

rigure'J3

~~~~~~~~----~~1

17 3-

WII)'diwrtiogvai••

$Witch cooneus

I

~

S)'Stem

supply

19 Syuem return

.20

Boiler

rc(~fva

BQi.Jer

Manual

"'21

lndired -Gua storage water

td

fO

ane

bOi

a.

~

ler

neq('d

io

Figure.J4

aJso ~ c;q,o

beader,

f

op"'""'

.acmM boiler

l

v·e

a~d~:arge:

Q(

tht~tm'4

~

th

thermo.stat wmi:Qals)

heaters-

Tbt

a

gecond.ary'copnc«ion off

ptgtt 27.

1

bjl

ptplo

OHW

"'fWISiat-valwend

g,

i~11t

aU¢

pq

~xa.mple-

indi~Ut

is

~"'llter

G\!'9()f

shown oonnect-

beater

coulj:)

the

ma1n

P.ut number

55()..142-783110

11

GV90+

Series

2 GAS•FIIIED

WATER

BOILER-

Boiler

Manual

Multiple

Figure

34 Piping

layout- typical for muniple GV90•

,,,

~·~··

I

'

~~

...

•

.e

~·

boiler

I

water

piping

!;>oilers

.

w~h

DHW storage heaters

(continued)

(4-l:;>oile

r system)

..

..

Jilnw

ft:

h«t-nlve.(ed

!

.boiMlocl

,.._

.

"""

•

l!tofy-,(:1,-M;n

llit.e~pace

~

1!.-yrF.tt

M•llifold

,.,

..,.u

.

&

'"""'

"'~

'I

£:(poao~l

otHant

1

!li)1

~m

til

riA'niaaiOr

9

s;

11cm_.,,unm:aai

J,a Cold

wuer-

·6D

fqr

fYJ*al

qv:npc

U:

S):ucom

...

1'.,.

jj

S,l

lll!

l"! IUIJRl

1JJ

Jkriler

rdid; 1o'

Jnsul

kd

re"

GY'oo-t

Pan

number

.ss

a-•e-783/ 1012

bqilerf

('<

~lMtd

i'*

(

rtq~pt,.

1

~

{retatnl-

(

Jiarhtayn

r

~lr ~~

Ji~:~~~

-RIL"

uwn

n

Afw

and

dldl.

JlolerMlntul

)

)

'-'

lilyoute.J

.._)CIIIi

lind

!Jpe)

Fqjure

'J.

-paF

,e

Jilti

n&o

•~

"U

27

GV90+

Series

2 OAS>f'IAED

WATER

BOtLER -

Boiler

ManuaJ

Multiple

Figure

36

Piping

layOUI

boiler

- typical f

~

,..

~

·-

...

water

or multiple GV90+ boil8fS, using isolaliQn excl1anger

Boiler-side

Heating

piping

circuit

system

circuit l

t

(contlnuedJ

u

l·

. -

f.

·~

--'

""=·'

...

..

.m

@ "'..:._

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U

ttl

aolation

~t

excm.nver tor.

I. la

rgt-

voluiUL'

.sy'Atm.t

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m.ln

utl

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t

ill

w~r

.

1.

Syitem.s

a-posed ta umuat

quantities

J.

Old

llllled

imidt
ti

...

rro~appticat

5.

Commu

p

6.

Kl_gbwar.erp~USU

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ill

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bclow

ol

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ale

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cial

lhtit~OS

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lr-ing prtssure

b~

Ji.ng

sym.m

(!aU

hWldUlg!.)

.

maknl

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watt:r~

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and

rust buildup

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-

36

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3.

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5.,

tr

htt1 ttcllangu fllll.nuf

~-.<ideao.Snol><

nqu.i.mnents

ft'Wf

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dp.aruion

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•15tem

~

boiler and

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ht:tt

fng

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~n

ht:a1excban!Jff

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shell~$id

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a-

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con

,sid<ari~"6

fl

ow

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manl1f

e.

UIOW!'I.

wn

relief

vaM

r!iping

11

'i

nok

may:

atutrer

and

t~cw

circuit

illi

ATCt

lll

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M rtqu

own

fot

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ror

ild113 heat

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28

P.art

nu

ulb«-

55()..

t

~2-7it.ll

101!

GV90+

Series

2 OAS·FIRED WATER BOILER -

Boiler

Manual

Venting

GV90+
suD!llled

lllll<in

d•acrtbedln

Every

00

appliance.

Inspect finished

thoroughly

dl

an
pro:vided

applicable

Fai

lure ro provide a

•ten

ptr$0nal in

If

NOTICE

tibe

cov-.ertd

can

in

staJiation>

assistance. Other configurations

be

available.

Where vent piping

en

mhNt•d

l inch

on

unbeated space.

Installations

r

equirementS

Fuel Gas
instaJiationsorCSA 8149.1 orB
for Canadian insta llations.

Use on

marual

tings.

If

used, • matonry

ONLY

vent

piping musr be instaJied

in dlis manual and
sealed. The chimney
only for
appliance or

to

the

straight.

an

d air pi

wi

th

cbimmey

ac~

teriiOr
The chim

m~r

alt)f

Fa

ll.u
personal injur
proper

&

air

bollero

with

olr ualng piping ond methode

bolter

NOT

com

carouldon end

thts m1oo11.

nwtt

common ve

to

ply wirh t

and with aU requirements

must

have

ven

ensu

-

bo

vented ond

tts own

nt

wi

th

any

t and

aJr

re aU

art

he instruct

general

piping

airtight

<Odes.

prope-rl)•-instaJJtd

t and air system

jury or

will

death.

cau..st

vent/air piping confignratlons

in

the

nor

bt

GV90+

app

lied for a particular

contact

boiler manual

Weii-Md.ain

lo

routed through

spac•> appt)• minimum

of

the

roil-faoed

length

Code,

fiberglass

of

the vent pipe

must compl

and

y wi

with the National

ANSI Z223.1 for

insulation

th

ly the materials listed in this

for

ven

t and

aJr

pipe

and

See

bo

and

Figure 40.

uood

air

pipet

page

chlmn•y

eo o PIPE

- The vent

aU

joints must be

33.

CHASE

and

as

instructed

musr be used

GV90+ boil

fireplace

chimney.

with

ping

ers.

NO

OTHER

can be connected

The chimney must be

no

offsets. and the

materials

must

comp

this instruction manual. The

must

be

fitted

with a sealed

optning..

of

be

ro

verify

rt

to comply could r

ry

through

the chim

in

ney

can be inspected.

ney

(and liner. if installed)

sptcted

ar

leasr once annu-

condition.

y.

death or substantia]

damage.

which

esu

lt

the in-

in

Yenll·

v•nt.

other

ions

of

seve-

re

for

may

in

the

locaJ

U.S.

149.2

fit

-

can

lor

a

ir

venr

ly

severe

When

common

The QVSIO+

applanc•.

the
boiler
may
vent. because the venr may

ANSI Z21.13.

rt:maining

removing a boller

bo

\"/hen an existing boiler

GV90+ boil

requires

cause a probl

is

on

the old common

vent

Its

system

..

r

cannot

er CANNOT

own

vent

em

for the appliances that rtmain on the old common

intended to

from

be

co...._

is

use

the existing common vent. The

and air piping,

be

roo

large.

check

for proper operati

vent

systm'l

an

..-ted

replaced with a

as

specified

The

following test. requi

.

existing

with..,.,

GV90+

in

this manual. This

on

of

the appliances

GV90+

Vent system verification

Ar

the time

followed

system

to

the

i

ngs

Existing

of

with

placed

removal
each
in

operati

of

appliance remaining connected tO the common \'tnting

<>n. whil

common vtnting sysrem

in the common

vent

·.-~nting

test

an

exis

ting boiler> the foll

e the o

rhe:r app

are not

in

system.

procedure

owing steps sha

liances

remaini

operation. Stal

any

ng

connected

unused

(The following is intended to test whether the spplisnces

remaining
sstlsfsctorlly.)

I.

Visually inspect the '\'tnting
and determine there is no bl
other detkiendes wbic.b could cause

2.

Te

windows
remaining conntcted

other

nor
fans,

ate at maximum

fireplace

3.

Place

structions.

4.

Te

burner

a

5.

Aft~r

to

~return

other gas-burning applian

Any

improper operati

so the installation con

- latesr edition. Correcr by re­determi

installations must

on

sn

existing vent system

st

·.-

~nt

syst~m-

and

Insofar as is practical. close aU building

all

doo

rs between the

to

spaces

of the buil

connected

such

as

r

ang~

to

dampers.

in operation

Adjust

st for

spillag~

operation.

cigarette,

cigar,

it has b«-n determined rhat

the common venting

doors,

ned

usi

ng

the appropri

comply with

ding. Tum on cloth

tbe common venting

hoods and bathroom exhausts, so th

sp.eed.

d:le

appliance

thermostat

at

draft

Use

the

or pipe.

windows.

on

of

f'o.rms

will

operate

sysrem for proper size and hori7.ontal pitch

ockage

or

restriction,

an

unsafe condition.

leakage, cor

rosion

doorS

spac~

in whi

ch the appliances

the common

Do not operate a summer exhaust

so

hood

rel

flame

system

exhaust

ce

to

common \'fnti

with the

·.-

~nting

sysrem

ar~

l

ocated

es dryers

system.

and

Tum

any

on

appliance

any

ey

will
fan

being inspected.

appliance w

ief

opening

of a matc.b

each

appliance remainingconntcted

F<>Uow

the l

ighting

ill

operate continuously.

aft~r

5 minutes

or

candle, or smoke from

properly \'fnts when tested as o

fans

.lireplacedampecs, and

their

Natio

pre't'iOUS

nal

ng

system

Fuel Gas

conditions

sho

uJd

Code,

of

be

corrected

ANSI

use.

sizing to approach the minimum size as

ate tabl

es

in Part 11

6149.1

or 8149.2 Installation

of

that

code

Code

. Canadian

exhaust

. Close

of

utJi

Z223.1

ot.,..

boiler.

red

b) •

ll

be

open

or

and

and

oper-

in-

main

ned

any

.

-

Part

number

550-14-2-783/10

12

29

GV90+

Series

2

oAs·FIRED

WATER

BOILER

-

Boiler

Manual

Venting

Provide

IA

WARMIMG

combustion

DIRECT

I

butdon

may

&

VENT

olr piping.

be

required.

air-

air:

- Tho lnotallotlon

DIRECT EXHAUST - The lnttlllotlon

combuatlon

ALL

APPLICAnON

combuatlon

lnc

M

Vent

1.

DIRECT

1.

2.

3.

and

air

v~nt

and

air pipi

r

oof

of

rhe buil

manual

configurations

ding.

See

Figure 39. page 32

and

VENT Installations

For

direct

venting.

bo

iler, following

a

ll

applicable codes.

Ventilation

u

~ 42.

page

If other appliances art located in r.he same

pr

O\ride

openings

the instructions

open

36.

If

combustio

as

direct~d

ventilation> the higher
in

reduced

air

openings

1lr

openlngt

In

th•

apace.

termination

ng

mu.sr

t~nninare

usi

ng onl)• one

piping material

combusti

ings are required for some spaces. See Fig-

shown

on

in Figure 42, page 36.

n and vtnrilatio n

above

and

component

general

mull

provide com-

In

oddhlon, vendlotlon openlngo

mutt

to the

boller

spac•.

S- Tho lnlllllodon

as

nCMidcld

options

our

the

sidewall

of

r.he

mer.hods

and

Figure 40. page 33 for allowable

s.

air

must

be

piped f'rom ou

in this

manua

space

with

air

open

the room

temperature in

li

fe.

does not

mUll

for

other

or

r.hrough

describfii in

tside

l.

and

compliant

the

GV%+ boiler,

ings are not provided

have

the

space may result

rconunuedJ

provide

provide

lppll-

the

r.h

is

ro

the

with

adequate

Combustion

Figure

36

Corrosive contaminants and sources

Producto

Spray
Permanent wave solutions
Chlorinated
Chlorine-based
Calcium cllloride used
Sodium chloride
Refrigerant leal<s
Paint or vamlsh removers
Hydrochloric acid/muriatic

Cemerlts and glues

Antistatic
Chlorine-type bleaches, detergents, and cleaning

solvents

to ovoid

cans containing chl

fabr

loood

air

contamination:

Ent...-e
not

lnRgure36

DO
Optn
a

Avoid areas

(rom laundry facilities. These
always contain conram i

waxes/cteaoo<s

thM

th•

contain

combutdon

any

of

the

.

NOT place

ings or inrake

swimming

swimming

used tor water softening

ic soft

ene<S

In

household laund<y rooms

combustion

term

pool>

for

subjtct

for

ro

oroA

iuorocarbo

pool chemicals

thawing

acid

used In clothes dryers

contaminants

inations

examp

exhaust

nants.

air

air supply

le.

artas

ns

wtll

near

fumes

w

ill

DIRECT

1.

Combustion
on dir

(S«- page 49 for a

pr

NOnCE

EXHAUST Installations

and

ect

O\ride

exhaust

r~uir

td

DO

NOT

at

alritud~s

fo

r DIRECT

alti

tudes

w nrll.arion

insra

ir

ope-ning i

air openi

sidewall v

abo\rt

above

llari

ons. Follow

ngs.

5>500

VENT

5>500

air

nstructions)

ent

applications (

must

DIRECT

feeL

feet

be prO\'ided

all

Sidewa

30

in

the

boiler

inst

ructions

and aU

EXHAUST

JJ

venting is only allowed

ducted

in

this

applicable

APPUCAnONS

combustion

room

manua

codes

air) at

ro

Adhesives
other

Exoossive dust and dirt

l

Areu

Dry

Swimming
Metal fabrication plants

Beau

Refrlgeratloo
Photo
Auto body shops
Plastic maoolacllJrlng plants
Fumiture

New

used

to

fasten bulldlng products and

simflar products

likely

to

hove

contamlnontt

dea:I\Jngllaundry areas and establshments

pools

ty

shops

repair shops

processing plants

I'Qf

inishing areas

bu

ilding construction

P-an

and

establishments

number

550-142

-783/1012