Boiler Manual - Weil-McLain

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GV90+ gas-fired water boiler — Boiler ManualService & maintenance (continued)Removing/cleaning/re-installing the recuperatorDisconnect the vent pipe from the recuperator1. The vent pipe must be disconnected (at the in-line flue drain, itemA in Figure 7, page 9).2. If the vent piping can be moved enough, loosen the flue pipe clampon the in-line flue drain. Then lift the flue pipe up and move asideslightly.3. If the vent piping cannot be moved, then cut the flue pipe carefullyso a coupling can be inserted later, or remove a section of vent pipeif using stainless vent pipe.Isolate boiler and drain partially1. Remove the jacket top panel and front panel.2. Allow time for the boiler to cool down if it has been operating.3. Close the isolation valves on the boiler supply and return connections.4. The boiler will have to be partially drained.a. Place a large pan under the boiler drain valve.b. Slowly open the drain valve and allow about a gallon of waterto drain out.c. Place the pan under the water connection flanges on the recuperator.d. Loosen the upper recuperator flange and allow any water inthe line to run out.e. Loosen the lower recuperator flange (return connection) andallow the water in the line and recuperator to drain out.5. After the recuperator and water lines have been drained, disconnectboth recuperator flanges.Remove the recuperator1. See Figure 102, page 95. Loosen the (4) nuts that secure the recuperatorto the boiler.2. Carefully slide the recuperator off of the (4) studs.3. Disconnect the plug-in connector on the thermal fuse (Figure102, page 95, item 27).4. Loosen the flue adapter clamp and remove the in-line drain fittingfrom the flue adapter.5. Dump any remaining water from the recuperator.6. Look through the flue adapter and locate the flueway drain holesas shown in Figure 84.7. Use a brush or other means to remove blockage from theseholes.8. Rinse the recuperator thoroughly.Re-install the recuperator1. Inspect the recuperator gaskets to make sure all are in good condition.Replace if there is any sign of damage.2. Attach the recuperator at the boiler connection.3. Secure with the four nuts.4. Re-connect the water connections to the upper and lower recuperatorflanges.5. Re-insert the in-line drain fitting into the recuperator vent adapter.Tighten the clamp to secure in place.6. Re-connect the plug-in connector on the thermal fuse (Figure102, page 95, item 27).Figure 84 Recuperator flueway drain holesRe-install the condensate trap and recuperator accesscover1. Replace the condensate trap and recuperator accesscover — tighten bolts securely (do not exceed 18 inchpounds,2 N-m, torque).If the recuperator shows signs of significantcorrosion or deterioration, contact Weil-McLain for recommendations on investigatingthe cause and replacing the recuperator ifnecessary.Make sure the recuperator access cover gasketis in good condition. Replace if necessary.Make sure the recuperator access cover andthe condensate trap are re-installed securely.Failure to comply with the above could resultin severe personal injury, death or substantialproperty damage.Re-connect the vent pipe1. If the vent pipe was lifted out, re-insert the vent pipeinto.2. If the vent pipe was cut, install a coupling in the ventline to allow re-connection.3. If a section was removed (stainless vent pipe), replacethe section.4. Re-connect the vent pipe to the in-line drain fitting andtighten the clamp.When replacing the vent pipe, follow all instructionsin this manual to ensure the ventis properly completed. Failure to properly thevent pipe could result in severe personal injury,death or substantial property damage.74Part number 550-142-054/1211
GV90+ gas-fired water boiler — Boiler ManualTroubleshootingVERIFY PROPER OPERATION AFTERSERVICING.Label all wires prior to disconnection when servicingcontrols. Wiring errors can cause improper and dangerousoperation.Never jumper (bypass) any device except for momentarytesting as outlined in Troubleshooting charts. Severepersonal injury, death or substantial property damagecan result.The IBC and boiler controls can malfunction if they getwet. Never try to use a control that has been flooded orwet. Replace it. Failure to comply can result in severepersonal injury, death or substantial property damage.The boiler contains ceramic fiber and fiberglass materials.Use care when handling these materials per instructionson page 107 of this manual. Failure to comply couldresult in severe personal injury.Figure 85 Connecting a manometer to checkair pressure switch. DO NOT use thisarrangement to check gas valveBefore troubleshooting1. Have a voltmeter that can check 120 VAC, 24 VAC, 24 VDC anda continuity checker.2. Check for 120 VAC (min. 102-max.132) to boiler.3. Make sure thermostat is calling for heat and contacts (includingappropriate zone controls) are closed. Check for 24 VAC betweenthermostat wire nuts and ground.4. Have an inclined manometer with 0 – 2” w.c. range.Check the following1. Wire connectors to IBC are securely plugged in at IBC and originatingcontrol.2. Hoses are properly and securely plugged in and are not damaged.Checking the air pressure switchDo not use manometer as shown in Figure 85 to test gasvalve outlet pressure. Where instructed in this manualto check gas valve outlet pressure, follow instructionscarefully, particularly regarding connection of manometer.Manometer fluid will cause permanent damage togas valve. Severe personal injury, death or substantialproperty damage can result.Check switch pressure setting1. See Figure 85.2. Remove both air pressure switch hoses from air pressure switch.3. Install tees and tubing as shown in Figure 85 to inclined manometer.4. Turn off gas valve and set thermostat to call for heat. Blower willrun but burner will not ignite.5. Check for 24 VAC between both air pressure switch terminals andground.6. If manometer reading is at least 1.0” w.c., but there isnot 24 VAC between both air pressure switch terminalsand ground, replace air pressure switch.Troubleshooting air pressure reading1. If manometer reading is lower than 1.4” w.c. check forpossible causes:• Blockage in hoses.• Loose blower wheel on motor shaft.• Blower motor not at proper rpm.• Blockage in air inlet or hose.• Blockage in flue pipe or termination.• Condensate trap filled w/condensate.Return to normal operation1. When pressure reading is proper and air pressure switchis operating properly, remove tees and reinstall hoses toair pressure switch.Part number 550-142-054/1211 75
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Boiler Manual - Weil-McLain

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