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Part number 550-142-054/0411
GV90+ gas-fired water boiler — Boiler Manual
4
How it works . . . . . . . . . . . . . .2
GV90+ Water Boiler . . . . . . . . .3
Please read before proceeding . . .5
Prepare boiler location . . . . . . .6
Installations must follow these codes: . . . 6
High altitude installations. . . . . . . . . . 6
Residential garage installation . . . . . . . 7
Check orifice plate — replace if necessary . 8
Install condensate trap. . . . . . . . . . . . 9
Install high altitude air pressure switch when
required (only above 5,550 feet) . . . . . . 9
Rotate the boiler into position . . . . . . 10
Perform hydrostatic pressure test. . . . . 11
Install water piping . . . . . . . . 12
General piping information. . . . . . . . 12
Install relief valve . . . . . . . . . . . . . 12
Expansion tank. . . . . . . . . . . . . . . 13
System water piping methods. . . . . . . 15
Circulators . . . . . . . . . . . . . . . . . 15
Simplified pipe/circulator selection . . . 15
Baseboard system piping — CIRCULATOR
zoning (primary/secondary) . . . . . . . 16
Baseboard system piping — ZONE VALVE
zoning (direct connection) . . . . . . . . 16
Radiator system piping . . . . . . . . . . 18
Single-zone radiant heating or heat pump 19
Adjust balancing valves . . . . . . . . . . 19
Multi-zone radiant heating system . . . . 20
Piping snow melt systems or combination
snow melt/space heating systems . . . . . 21
Water chiller systems . . . . . . . . . . . 22
Multiple boiler installations . . . . 23
Placing multiple boilers . . . . . . . . . . 23
Controlling multiple GV90+ boilers . . . 23
Piping multiple GV90+ boilers . . . . . . 23
Multiple boiler water piping. . . . 24
Easy-Fit® piping installation . . . . . . . 24
Venting & air — general. . . . . . 29
When removing a boiler from an existing
common vent system . . . . . . . . . . . 29
Existing vent test procedure. . . . . . . . 29
Provide combustion air:. . . . . . . . . . 30
Vent and air termination options. . . . . 30
DIRECT VENT installations . . . . . . . 30
DIRECT EXHAUST installations. . . . . 30
Combustion air contamination: . . . . . 30
Manifolded combustion air option for
DIRECT VENT multiple boiler installations
31
Air manifold sizing . . . . . . . . . . . . 31
Commonwealth of Massachusetts
installations . . . . . . . . . . . . 34
Vent termination requirements . . 35
DIRECT VENT — Boiler room air
openings . . . . . . . . . . . . . . 36
DIRECT VENT — Sidewall with W-M
vent/air plate . . . . . . . . . . . . 37
DIRECT VENT — Sidewall with sepa-
rate pipes. . . . . . . . . . . . . . 39
DIRECT VENT — Sidewall with 3”
concentric . . . . . . . . . . . . . 41
DIRECT VENT — Vertical with sepa-
rate pipes. . . . . . . . . . . . . . 43
DIRECT VENT — Vertical with 3”
concentric . . . . . . . . . . . . . 45
Concentric termination assembly
(sidewall or vertical). . . . . . . . 47
Vent and air piping and boiler con-
nections . . . . . . . . . . . . . . 48
DIRECT EXHAUST & DIRECT VENT . 48
Follow termination instructions . . . . . 48
Installing vent and air piping . . . . . . . 48
DIRECT EXHAUST ONLY . . . . . . . . 48
DIRECT EXHAUST — Boiler room air
openings . . . . . . . . . . . . . . 49
Combustion air provision. . . . . . . . . 49
Sizing combustion air openings . . . . . 49
Special considerations . . . . . . . . . . . 49
GV90+ boiler WITHOUT other appliances
in room . . . . . . . . . . . . . . . . . . . 50
Air openings . . . . . . . . . . . . . . . . 50
GV90+ boiler WITH other appliances in
room . . . . . . . . . . . . . . . . . . . . 50
DIRECT EXHAUST — Sidewall . . 51
DIRECT EXHAUST — Vertical. . . 53
Gas piping . . . . . . . . . . . . . 54
Connecting gas supply piping. . . . . . . 54
Natural Gas. . . . . . . . . . . . . . . . . 55
Propane Gas . . . . . . . . . . . . . . . . 55
Wiring . . . . . . . . . . . . . . . 56
Field wiring. . . . . . . . . . . . . . . . . 56
Start-up. . . . . . . . . . . . . . . 59
Freeze protection (when used) . . . . . . 59
Clean system to remove sediment . . . . 59
Water chemistry . . . . . . . . . . . . . . 59
Antifreeze. . . . . . . . . . . . . . . . . . 59
Check for gas leaks. . . . . . . . . . . . . 60
Fill and test water system . . . . . . . . . 60
Verify gas/air orifice plate . . . . . . . . . 61
Check thermostat circuit(s). . . . . . . . 61
Inspect/fill condensate system . . . . . . 61
Final checks before starting boiler . . . . 62
To start the boiler . . . . . . . . . . . . . 62
If boiler does not start correctly . . . . . 62
Check system and boiler after start-up. . 62
Gas valve adjustment — altitude over 5,500
feet ONLY . . . . . . . . . . . . . . . . . 62
Final checklist . . . . . . . . . . . . . . . 64
Annual start-up and general mainte-
nance schedule . . . . . . . . . . 67
Annual start-up . . . . . . . . . . 68
Address reported problems . . . . . . . . 68
Inspect boiler area . . . . . . . . . . . . . 68
Inspect boiler interior . . . . . . . . . . . 68
Inspect condensate drain system . . . . . 68
Inspect all piping for leaks . . . . . . . . 68
Inspect gas piping . . . . . . . . . . . . . 68
Inspect the water system. . . . . . . . . . 68
Inspect expansion tank . . . . . . . . . . 68
Inspect air openings . . . . . . . . . . . . 69
Inspect vent system and air piping . . . . 69
Inspect boiler heating surfaces . . . . . . 69
Inspect recuperator . . . . . . . . . . . . 69
Inspect igniter . . . . . . . . . . . . . . . 69
Inspect temperature mixing system . . . 70
Inspect limit controls and cutoffs. . . . . 70
Inspect gauges . . . . . . . . . . . . . . . 70
Inspect blower motor . . . . . . . . . . . 70
Inspect oiled-bearing circulators . . . . . 70
Inspect boiler relief valve . . . . . . . . . 71
To complete Annual Start-up, perform
startup and checks: . . . . . . . . . . . . 71
Review with owner. . . . . . . . . . . . . 71
Service & maintenance . . . . . . 72
Cleaning boiler heating surfaces . . . . . 72
Inspecting and cleaning the recuperator. 73
Troubleshooting . . . . . . . . . . 75
VERIFY PROPER OPERATION AFTER
SERVICING. . . . . . . . . . . . . . . . . 75
Before troubleshooting . . . . . . . . . . 75
Check the following . . . . . . . . . . . . 75
Checking the air pressure switch . . . . . 75
Igniter. . . . . . . . . . . . . . . . . . . . 76
Gas Valve . . . . . . . . . . . . . . . . . . 76
Blower Housing . . . . . . . . . . . . . . 76
Thermal fuse . . . . . . . . . . . . . . . . 76
Return temperature sensor . . . . . . . . 76
IBC (integrated boiler control)
. . . . . . 77
IBC indicator lights — lockout modes. . 77
IBC indicator lights — non-lockout modes
77
Replacement parts . . . . . . . . 89
Dimensions and ratings. . . . . 100
NOTES . . . . . . . . . . . . . . 104
NOTES . . . . . . . . . . . . . . 106
Handling ceramic fiber and fiber-
glass materials. . . . . . . . . . 107
Installation and service
certificate . . . . . . . . . . . . 108
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