Boiler Manual - Weil-McLain

GV90+ gas-fired water boiler — Boiler ManualAnnual start-upAnnual start-up only by qualifiedservice technicianAddress reported problems1. Inspect any problems reported by owner and correct before proceeding.Inspect boiler areaThe boiler should be inspected and started annually,at the beginning of the heating season, onlyby a qualified service technician. In addition, themaintenance and care of the boiler designated inFigure 77, page 67 and explained on the followingpages must be performed to assure maximumboiler efficiency and reliability. Failure to serviceand maintain the boiler and system could resultin equipment failure.Electrical shock hazard — Turn off power tothe boiler before any service operation on theboiler except as noted otherwise in this instructionmanual. Failure to turn off electrical power couldresult in electrical shock, causing severe personalinjury or death.1. Verify that boiler area is free of any combustible materials, gasolineand other flammable vapors and liquids.2. Verify that air intake area is free of any of the contaminants listedin Figure 36, page 30. If any of these are present in the boiler intakeair vicinity, they must be removed. If they cannot be removed,reinstall the air and vent lines per this manual.Inspect boiler interior1. Remove jacket top and front door to inspect interior of boiler.2. Vacuum any sediment and components.Do not use solvents to clean any of the boiler components.The components could be damaged, resulting inunreliable or unsafe operation.Inspect condensate drain system1. Inspect the condensate trap hose for deterioration.2. Check for any obstructions in the trap hose by squeezing thetubing.3. If there is any doubt the condensate drain system is flowing freely,remove the clamp and hose from the bottom of the recuperator.Slide a funnel outlet into the trap hose and pour water through. Itshould exit at the termination of the condensate drain line.Inspect all piping for leaksEliminate all system or boiler leaks. Continualfresh make-up water will reduce boiler life.Minerals can build up in sections, reducingheat transfer, overheating heat exchanger, andcausing heat exchanger failure. Leaking watermay also cause severe property damage.1. Inspect all water and gas piping and verify to be leakfree.2. Look for signs of leaking lines and correct any problemsfound.3. Check gas line using procedure on page 54.Inspect gas piping1. Sniff near floor and around boiler area for any indicationof a gas leak.2. Test gas piping using bubble test, per page 54, ifthere is any indication of a leak.Inspect the water system1. Verify all system components are correctly installed andoperational.2. Check the cold fill pressure for the system. Verify it iscorrect (usually around 12 PSIG).3. Watch the system pressure as the boiler heats up (duringtesting) to ensure pressure doesn’t rise too high.Excessive pressure rise indicates expansion tank sizingor performance problem.4. Inspect automatic air vents and air separators. Removeair vent caps and briefly press push valve to flush vent.Reinstall caps. Make sure vents do not leak. Replace anyleaking vents.Check water system chemistry1. Check system water chemistry (pH and hardness). Seeinstructions beginning on page 59.2. Check glycol and glycol inhibitor levels if using glycol/water mixture. See instructions beginning on page 59.3. Check Sentinel X100 inhibitor level in the water usingthe Sentinel X100 Inhibitor Test Kit. Follow instructionssupplied with the kit. Add X100 inhibitor if needed tobring to the correct level. (See Figure 96, page 89 forpart numbers.)Do not use petroleum-based cleaning orsealing compounds in boiler system. Severedamage to boiler will occur, resulting insubstantial property damage.68Part number 550-142-054/1211