Weil-McLain Series 1 Boiler User's Manual
Contents
1. Figure Fitting Figure Fitting 8 Description Description IM 252 Q 1x 1x1 2 Tee 1 1 2x3 Nipple B ix3Niple 31 J3 Street Elbow P 12x 1 4 bushing SH ix2Nppe M 1 21 2 Nipple 1 Close Nipple 1 2 Close Nipple 3 x3Close Nipple U2Elbow P 1 2 2 1 2 Nipple Weil McLain Sales Ref No 3 Figure No Mixing Valve 10C408 2 Circulator Taco 007 10C195m 101958 oC 195a 10 195 __ Circulator Bell amp Gossett 120 roc 194m 10 194 3 circulator Flange T 10C296m 10C296m 10 296 10 296 Greuctor Flange Bell ioczssm 10C298m 10 2 4 circulator Gasket Taco 10C307m 10 307 10307 Circulator Gasket Bell amp Gossett 10C305m 10C305m 10C305m 5 Wiring Hamess Control Module to Circulator 1 410_ 410_ 41 10 410 6 Pressure Temperature Gauge 2 1 2 SSHK L 7 Relief Valve 3 4 30P8I 106 W9Ii 10 19 IOC 199 a Me 7 Lj ww VE We Available from local supply house DOE HEATING BOILER INPUT CAPACITY MODEL BIUH Based on standard test procedures prescribed by the United States Department2. WEIL Mc LAIN GV BOILER em BOILER MANUAL T an INCLUDES INSTALLATION START UP MAINTENANCE PARTS GAS FIRED POWER VENTED OPTIONAL OUTSIDE COMBUSTION AIR TO THE USER Boiler Manual is to be used by your qualified heating installer service technician User s Information Manual is for your reference Regular service by a qualified service technician is recommended 5 W A RNING Follow all instructions in proper order to prevent personal injury or death Read all instructions before installing Also refer to Gas Control Supplement and other packaged instructions Consider piping and vent locations when determining boiler location Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee Part Number 550 141 601 0490WP INSTALLATIONS MUST FOLLOW THESE CODES 4 PROVIDE CLEARANCES AROUND BOILER 4 PROPERLY LOCATE VENT TERMINATION 5 SELECT COMBUSTION AIR SOURCE 5 LAY A FOUNDATION isse n 5 Section Boiler Preparation HOW TO PLACE 6 MAKE HYDROSTATIC PRESSURE 6 Section C Water Piping PIPING SINGLE 2 7 8 PIPING MULTIPLE 2 9 PIPING FOR SYSTEMS BELOW 1409F 10 Section D Venting Combustion Air VENTING THRU SIDE
3. e National Electrical Code and any other national state provincial or local codes or regulations having jurisdic tion Safety wiring must be N E C Class 1 e Boiler must be electrically grounded as required by N E C ANSI NFPA 70 latest edition e In Canada C S A C22 1 C E C Part 1 CONNECT WIRING Thermostat 1 Install on inside wall away from influences of drafts hot or cold water pipes lighting fixtures television sunrays or fireplaces 6 2 3 Follow instructions with thermostat Ifit has a heat an ticipator set heat anticipator in thermostat to match power requirements of equipment connected to it ignition control and gas valve zone valve contacts etc Wiring diagram on boiler gives setting for stan dard equipment ignition control and gas valve Thermostat wires are labeled T T on boiler Remove label before connecting as shown in Figure 18 Junction Box furnished l 2 Fused disconnect or service switch 15 amp recom mended may be mounted on this box Some local codes may prohibit installation of fused disconnect or service switch on boiler Connect as shown in Figure 18 DETERMINE IF WATER TREATMENT IS NEEDED l Never use petroleum based stop leak compounds Water seal deterioration will occur resulting in leak age between sections Consult local water treatment companies for unusu ally hard water areas above 7 grains h
4. BLOWER HOUSING A FIRE OR EXPLOSION CAUSING SEVERE PERSONAL INJURY OR PROPERTY DAMAGE CAN RESULT YOU 7N SUSPECT A PROBLEM REPLACE BLOWER HOUSING Blower Assembly Weil McLain Sales Ref No GV 4 ev s Gv 6 10C379 10C379 10C379 10C379 10 381 10C38 Description Burner Replacement Kit Including Burner Cone and Ring Assembly Blower Flange Gasket Ignitor Ignitor Screws ignitor Washers ignitor Gasket Blower Assembly Including Blower Housing Observation Port Window Blower Housing Cover Plate Blower Motor Mounting Brackets Washer Hold Down Bracket Lock Nuts Motor Mount Grommels Blower Motor Blower Wheel Magnetic Washer Silicone Sealant Screws Blower Flange Gasket Ignitor Ignitor Screws Ignitor Washers ignitor Gasket Blower Motor Replacement Kit Including Blower Motor Motor Mount Grommets Screw Lock Nuts 8 Allen Wrench Pressure Switch Inlet Air Tube w Grill Vent Replacement Kit including Vent Ell w Drain Silicone Sealant RTV 700 Gas Air Manifold Assembly Including Gas Air Manifold Gas Tubing Washers Screws Conversion Kit Natural to Propane Including Propane Orifice Plate Label Conversion Kit Propane to Natural Including P Natural Orifice Plate Label Boiler Trim Assembly i e 4 5kE KITS P 24
5. air inlet hose with new wire tie blower motor wiring harness to control module ignitor harness connected to ignitor plug 6 Install control tray 7 Besure all wiring and hose connections are secure and correct 2 am INSIDE COMBUSTION AIR CONTAMINATION All boilers experience some condensation in the section assembly during start up Unlike most conventional boil ers condensation is minimized in the GV by a built in mixing valve that maintains boiler return water tempera ture above 140 F The condensate from flue gas is slightly acidic In most cases the pH level is not harmful to vents or drains When combustion air is contaminated by vapors from products in areas listed below the acidic levels in the condensate increase Higher acidic levels attack many materials in cluding stainless steel commonly used in high efficiency systems The GV boiler can use special corrosion resistant non metallic vent material You may however choose to use outside combustion air for one or more of these reasons e installation is in an area containing contaminants listed below which will induce acidic condensation e you want to reduce infiltration into your home through openings around windows and doors e you are using AL29 4C stainless steel vent pipe which is more corrosion resistant than standard metallic vent pipe In extremely contaminated areas this may also experience deterioration 1 Products causing contaminat
6. A330ALG BRACKET WHITE PRESSURE SWITCH HOSE RED PRESSURE SWITCH HOSE INLET AIR HOSE AND WIRE TIE REMOVING REPLACING BLOWER ASSEMBLY FIGURE 20 To remove blower assembly Wait until ignitor is cooled down be fore proceeding Turn off power and gas to boiler Fail ure to do so can cause severe personal injury death and property damage 1 Remove control tray 2 Disconnect gas tubing from gas valve left hand thread pressure switch hoses hose from gas valve to gas air manifold air inlet hose blower motor wiring harness from control module ignitor harness connected to ignitor plug blower support bracket 3 Remove 2 ignitor screws and washers Carefully re move ignitor Use care when handling ignitor very brittle 4 Remove nuts from studs at blower housing mounting bracket 5 Grasp blower housing and pull free from studs Tum clockwise until blower assembly can be removed safely from inside of boiler 6 Burner cone and ring assembly can be removed for inspection To replace blower assembly 1 Re install burner cone and ring assembly into combus tion chamber opening 2 Place blower housing gasket over studs at combustion chamber opening 3 Position blower assembly over studs Install nuts and tighten 4 Install ignitor and ignitor gasket Fasten with screws and washers 5 Connect gas tubing to gas valve left hand thread pressure switch hoses hose from gas valve to gas air manifold
7. TYPE TANK FROM ADDITIONAL ZONES SEE NOTE RELIEF VALVE DISCHARGE PIPING AUTOMATIC AIR VENT COMBINATION FILL VALVE CHECK VALVE STRAINER AND PRESSURE REDUING VALVE PRESSURE COLD WATER TEMPERATURE GAUGE FILL ISOLATION VALVE DIAPHRAGM TYPE TANK TO SYSTEM ORTO ADOMONA eie PIPING WITH DIAPHRAGM TYPE EXPANSION TANK FIGURE 5 1 Pipe properly see Figure 5 to avoid improper operation 4 ASME requires a low water cut off device when boiler is installed above radiation level or by certain state or local codes or insurance companies Use low water cut off designed for water installations Electrode probe type is recommended Purchase and install in tee in supply piping above Doiler and damage to boiler or building 2 Ifsystem is to comply with ASME codes an additional high temperature limit is needed Purchase and install in To System piping between boiler and isolation valve 5 Ensuretank pressure and size will handle system fill 3 Install relief valve in tapping on top of back section and water volume See Table II WARNING Relief valve discharge piping e Fill pressure may be adjusted at tank e Additional tanks may be connected to must be piped near floor close to floor drain to eliminate po tees in system See Table II for sizing tential of severe burns Do not pipe to any area where freezing could occur 6 Install automatic air vent as shown in F
8. air inlet or less than 3 feet from any other building opening ar any gas service regula tor SELECT COMBUSTION AIR SOURCE Outside or inside combustion air can be used Outside air will maximize efficiency and minimize exposure to contaminants Read Appendix page 22 before using inside air 1 If outside air is used a outside air intake piping is all you need See page 12 for instructions b provide for adequate ventilation when installed in tight spaces See page 4 2 If inside combustion air is used a In conventional frame masonry or metal con struction infiltration is normally adequate for boilers in unconfined rooms b In unusually tight construction provide outside air as stated in 2d oe c For boilers in confined rooms provide 2 permanent openings one within 12 inches from ceiling and one within 12 inches from floor of room Each opening must be at least 1 sq inch per 1000 Btuh boiler input but not less than 100 sq inches Openings must freely connect with areas having adequate air flow from outside d When outside air is needed provide 2 openings as outlined above Openings must connect directly or by ducts with outdoors or spaces crawl or attic that freely connect to outside Size as listed below 1 1 sq inch per 4000 Btuh boiler input for direct outside air through outside wall or through ver tical duct directly to outside 2 1 sq inch per 2000 Btuh boiler inpu
9. area or move the selector arm Never use tools If the knob or arm for gas Be sure to smell next to the floor because some gas is will not push in or turn by hand don t try to repair it calla heavier than air and will settle on the floor qualified service technician Force or attempted repair may result in a fire or explosion WHAT TO DO IF YOU SMELL GAS D Do not use this appliance if any part has been under water ES put Immediately call a qualified service technican to inspect the appliance and to replace any part of the control system and do not use any phone in your building e Immediately call your gas supplier from a neighbor s any gas control which has been under water phone Follow the gas supplier s iristructions OPERATING INSTRUCTIONS STOP Read the safety information above 2 Set the thermostat to lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand NOTE Use the picture that corresponds with your valve WHITE RODGERS ROBERTSHAW X E POSITION INDICATOR 5 Push in gas control knob slightly and turn clockwise N 5 Depress and move selector arm left C to OFF to OFF Note Arm cannot be turned to OFF unless arm is pushed NOTE Knob cannot be turned to OFF unless knob is
10. property damage or personal injury 1 Gases will form white plume in winter Plume could obstruct window view Prevailing winds could cause freezing of condensate and water ice build up on building plants or roof Locate or guard vent to prevent accidental contact by people or pets 4 DO NOT terminate vent in window well stairwell alcove courtyard or other recessed area 5 Vent must terminate at least 4 feet below or 4 feet horizontally from any door window or gravity air inlet to building 6 This vent must not be less than 7 feet above grade when located adjacent to public walkways 7 Terminate vent at least 3 feet above any forced air inlet located within 10 feet 8 Vent must terminate at least 4 feet horizontally and in no case above or below unless a 4 ft horizontal distance is maintained from electric meters gas meters regulators and relief equipment 9 DO NOT terminate vent above any door or window Condensate can freeze causing ice formations 10 Locate or guard vent to prevent condensate from dam aging exterior finishes 11 DONOTextend exposed vent pipe outside of building Condensate could freeze and block vent pipe 12 Terminate vent at least 6 feet away from adjacent walls 13 DO NOT terminate vent closer than 5 feet below roof overhang 14 Terminate vent at least 1 foot above grade including normal snowline 15 Canada do not terminate vent less than 6 feet from another combustion
11. top panel and check for piping leaks around circulator mixing valve relief valve and other fittings Repair if found DO NOT use petroleum based stop leak compounds leakage between sec tions will occur vd during heating season Check that boiler area is free from combustible materials gasoline and other flammable vapors and liquids Check for and remove any obstruction to the flow of combustion or ventilation air to boiler 20 Section Maintenance iind during heating season 3 4 Open jacket top panel and check for piping leaks around circulator mixing valve relief valve and other fittings If found repair at once DO NOT use petroleum based stop leak compounds leakage be tween sections will occur Visually inspect burner flame and ignitor glow page 17 Visually inspect venting system for proper function deterioration or leakage Check air vents for leakage Periodically during heating season 2 3 4 Check relief valve Refer to manufacturer s instruc tions on valve Test low water cut off if used Refer to manufac turer s instructions Visually inspect condensate drain hose for proper operation or deterioration Check for plugged con densate drain by checking for 1 or more inches of water in vent ell Clean screen in vent termination and air intake Every 6 months 1 Oil blower motor With boiler power shut off lift up control tray Place a few d
12. 204 118204 118204 118204 Inf Section 3915 Repair Kit Required 118205 118205 Back Section 3918 Repair Kit Required 118206 118206 118206 Front Replacement Sections including Square Cut Seals 2 Silicone Sealant Tie Rod Nuts Rod Washers Water Tubing Mo Adapters 1 N P T Water Tubing Pump to Return Blower Flange Gasket itor Gasket Screws Studs Nuts Lock Washers Kit Int Back Replacement Sections Including Square Cut Seals 2 Silicone Sealant Tie Rod Nuts Tie Rod Washers 118208 118208 Blower Housing Support Thermo Disc Kit Including 3T Block Switch Block Switch Clip Wire Ties Jacket Assembly Weil McLain Sales Ref No Description Gv 3 Gv 4 5 Gv e Jacket Replacement Carton Including Lett Side Jacket Panel Right Side Jacket Panel Back Jacket Panel Interior Jacket Panel Pocket for Front Panel Front Jacket Panel Top Jacket Panel Limit Pressure Switch Bracket Labels Screws For reference only not included in jacket carton Vent Parts Vent Pipe 3 10 length wmo O 90 Sweep Elbow long radius 3UES90 45 Gong radu aues Plexco PLEXVENT Descriptio Vendor Part Number De C 901220 90 Sweep Elbow radius 902299 45 Elbow long radius 903958 98 3UC m 25 mmm M DO NOT DISASSEMBLE WM
13. C2 y 1 RETURN GAS CRATE DIMENSIONS APPROX BOILER CONNECTION OUTSIDE MEASUREMENTS IN SHIPPING WT MODEL SUPPLY IN SIZE IN LENGTH HEIGHT LBS Lue on 32 z j 5 gems NE See X s 2 s 55 pues ed ni 3 2 4 w eee ERE TERME 7 232 4 4 MANUAL MAIN SHUTOFF GAS VALVE r UNION BY OTHERS Vent Eli with Condensate Drain and Trap Vent Air Intake Sidewall Termination Kit 40VA Transformer Electrical Junction Box 30 PSI ASME Relief Valve Water Temperature Limit Switch Section Block Temperature Limit Switch Combination Pressure Temperature Gauge Drain Valve ADDITIONAL EQIPMENT Weil McLain 5 Year Homeowner Protection Pian Fill Trot System diaphragm type expansion tank fill and check valve automatic alr vent and fittings 109 for sizes 3 thru 5 110 for size 6 Shipped in separate carton C3
14. ING PLATE SEE NOTE 4 GALVANIZED ONFIG 14B SLEEVE SEA b PPO CONNECTIONS ME SLEEVE WITH SILICONE SEALANT PARTS PROVIDED OTHERS COMBUSTIBLE SIDEWALL TERMINATION WITH VENT COUPLING TERMINATION FIGURE 14A REQUIRED NON METALLIC COUPLING OF CERTIFIED MATERIAL TURN DOWN ELBOW AND NIPPLE MAY BE ATTACHED TO COUPUNG FINAL TERMINATION MUST HAVE SCREEN AS SUPPLIED BY VENT MANUFACTURER ALUMINUM PLATE SEAL ALL CONNECTIONS WITH SILICONE SEALANT PARTS PROVIDED BY OTHERS NON COMBUSTIBLE SIDEWALL TERMINATION WITH VENT COUPLING TERMINATION FIGURE 14B Instructions on page 11 must be followed Also refer to page 5 to review sidewall venting locations Construct as shown in Figures 14 and 14A or B Check all vent joints and seams for gas tight seal Repair if leaking Support piping a horizontal runs atleast every 5 feet Canada every 3 feet b vertical runs use braces under elbow or pipe near elbow every 5 feet Canada every feet Maintain 1 minimum clearance from combustible materials to vent pipe 3 B mom poc pc a RS MA Shae ae VENTING THROUGH ROOF OR UNUSED CHIMNEY SEAL ALL CONNECTIONS WITH SILICONE SEALANT ASIOALG VENTING THROUGH UNUSED CHIMNEY FIGURE 15 1 Instructions on page 11 must be followed 2 Vent pipe must extend a through entire length of unused
15. LL TERMINATION WITH W M VENT AIR INTAKE TERMINATION FIGURE 13A 2 ARN AIR INTAKE CAP SIDE VIEW NON COMBUSTIBLE SIDEWALL TERMINATION WITH W M VENT AIR INTAKE TERMINATION FIGURE 13B Instructions on page 11 must be followed Also refer to page 5 to review sidewall venting locations Use only W M vent air intake terminal kit W M Sales Ref No 11B223 provided with boiler Install as shown in Figures 13 and 13A or B If inside combus tion air will be used do not remove knockout in plates ONLY if inside combustion air is used a turndown non metallic termination elbow and nipple may be attached to vent outlet Elbow must have screen as supplied by vent manufacturer Donot cover upoutside cap and plate with any exterior building material such as siding or wood Check all vent joints and seams for gas tight seal Repair if leaking Support piping a horizontal runs at least every 5 feet Canada every 3 feet b vertical runs use braces e under elbow or pipe near elbow e every 5 feet Canada every 3 feet Maintain 1 minimum clearance from combustible materials to vent pipe lt VENTING THROUGH SIDEWALL USING VENT COUPLING TERMINATION SEAL ALL CONNECTIONS WITH SILICONE SEALANT PITCH UP 1 4 PER FOOT A230ALG VENTING THROUGH SIDEWALL WITH VENT COUPLING TERMINATION FIGURE 14 ALUMINUM PLATE ALUMINUM COUPL
16. NE ISOLATION VALVE 3 ISOLATION VALVE FLOW CONTROL VALVE AS20ALG CIRCULATOR ISOLATION VALVE VALVE ius DRAIN VALVE DRAIN VALVE TO SYSTEM FROM SYSTEM IMPORTANT SEE ITEM 1 BELOW MULTIPLE ZONING WITH CIRCULATORS FIGURE 8 SUPPLY RETURN ADDITONAL ZONE2 ZONE 1 ZONE 1 ZONE2 ADDITONAL ZONE ZONE ISOLATION VALVE ZONE VALVE d ISOLATION VALVE zl DRAIN VALVE DRAIN VALVE ISOLATION VALVE ISOLATION VALVE TO SYSTEM FROM SYSTEM IMPORTANT SEE 1 BELOW MULTIPLE ZONING WITH ZONE VALVES FIGURE 9 1 DO NOT REMOVE CIRCULATOR AND MIXING VALVE LOCATED INSIDE BOILER 9 2 Follow instructions on pages 7 and 8 to install piping near boiler 3 See Figure 8 or 9 to complete installation PIPING FOR SYSTEMS REQUIRING TEMPERATURES BELOW 140 F SUPPLY RETURN ADDITONAL ZONE2 SINGLE ZONE SINGLE ZONE ZONE 2 ADDITIONAL OR ZONE 1 OR ZONE 1 ZONE ISOLATION VALVE CIRCULATOR SYSTEM TEMP GAUGE o FLOW CONTROL VALVE SYSTEM TEMP GAUGE 1 AO4OALG i i T X DRAIN VALVE SYSTEM TEMP CONTROLS SYSTEM TEMP GAUGE ISOLATION VALVE ISOLATION VALVE TO SYSTEM FROM SYSTEM IMPORTANT DO NOT REMOVE CIRCULATOR AND MIXING VALVE LOCATED INSIDE BOILER PIPING WITH CIRCULATORS FIGURE 10 SUPPLY RETURN ADDITIONAL ZONE2 SINGLE ZONE ADDITIONAL ZONE2 SINGLE ZO
17. NE ZONE OR ZONE 1 ZONE OR ZONE 1 ISOLATION VALVE ISOLATION VALVE ZONE VALVE SYSTEM SYSTEM TEMP GAUGE TEMP GAUGE AA40OALG CIRCULATOR DRAIN VALVE SYSTEM TEMP CONTROL SYSTEM TEMP GAUGE ISOLATION VALVE ISOLATION VALVE TO SYSTEM FROM SYSTEM IMPORTANT DO NOT REMOVE CIRCULATOR AND MIXING VALVE LOCATED INSIDE BOILER PIPING WITH ZONE VALVES FIGURE 11 1 In most systems this type of piping is not required If system water temperature requirements are less than 140 F use piping as shown in Figure 10 or 11 If system piping is plastic without an oxygen barrier a heat exchanger should be used Section D Venting and Combustion Air Supply These instructions take precedence over vent manufacturer s instructions SELECT VENTING MATERIALS AGA CGA certified venting materials Plexco PLEXVENT Hart and Cooley ULTRAVENT AL29 4C Stainless Steel Using other venting materials can W result in personal injury death property damage Use suitable 3 material for outside combustion air such as Dryer vent Galvanized steel PVC 3 LD FOLLOW VENTING REQUIREMENTS 1 DO NOT use existing chimney as raceway if another appliance or fireplace is vented into or thru chimney 2 See Appendix page 22 when existing boiler is removed from common venting system 9 3 DO NOT connect e any other appliance to vent piping e multiple boil
18. National Fuel Gas Code ANSI Z223 1 latest edition Correct by resizing to approach the minimum size as determined using the appropriate tables in Appendix G of that code REDUCED INPUT FOR VENT LENGTH 96 INPUT Se 99 97 95 e 90 0 20 40 60 80 100 TOTAL EQUIVALENT LENGTH IN FEET FROM BOILER TO TERMINATION o Um Section Parts Section Assembly 24 Jacket Assembly 25 Vent Parts 25 Blower Assembly 26 Boiler Assembly 27 REPLACEMENT INSTRUCTIONS Before replacing any parts on the boiler 1 Turn off power 2 Shut off gas supply Refer to appropriate drawing on following pages for parts replacement Replacement parts can be ordered or purchased through a local Weil McLain distributor When ordering specify GV Boiler and include description and part number of replacement part Some parts are stock items Ill and can be purchased from a local supply house 23 umm Section Assembly aedi 59163911 Ref BETTE Description Block Assembly Including Front Section 3914 Int Section 3915 qty for boiler size Back Section 3918 Square Cut Seals 2 Silicone Sealant Tie Rods Tie Rod Nuts Tie Rod Washers Water Tubing Male Adapters 1 N P T Water Tubing Pump to Return Blower Flange Gasket ignitor ignitor Gasket Screws Lock Washers Studs Nuts 118200 Front Section 3914 Repair Kit Required 118
19. Prepare boiler as shown in Figure 4 Leave boiler on skid until installation site is ready 2 Connect fill water supply through drain valve Fill l Verify that orifice plate stamping is proper size for boiler with water be sure bleed valve is open When boiler and is for proper fuel red propane natural water flows from bleed valve shut off water Close metal natural Boiler is shipped ready for natural gas bleed valve Slowly re open j drain valve until test decns boiler to iad instruc pressure of not more than 45 psi is reached on the tons included with propane orilice plate pressure gauge TEST AT NO MORE THAN 45 PSI for than 1 2 Move boiler skid next to installation site more MAn Omi es WARNING Do not leave boiler unattended 8 Position boiler on site as follows as shown in A cold water fill could expand Figure 3 and cause excessive pressure Carefully tip boiler over onto base rail legs 3 EE pressure has been main DANGER Boiler is heavy Take pre Bguout test Bu to avoid personal 4 Check for leaks Repair if found 5 Cut shipping strap and remove skid 5 Remove fill water supply from drain valve Drain Install jacket back panel with 4 screws from trim bag 6 Remove plugs from relief valve tapping and water assembly supply and return tappings 6 Section C Water Piping PIPING SINGLE ZONE WITH DIAPHRAGM
20. WALL WITH W M VENT AIR INTAKE TERMINATION 11 12 VENTING THRU SIDEWALL WITH VENT COUPLING TERMINATION 11 amp 13 VENTING THRU ROOF OR UNUSED 11 amp 14 um oc Table of Contents Section J Appendix INSIDE COMBUSTION AIR CONTAMINATION 22 REMOVING BOILER FROM COMMON VENTING 22 VENT DERATING 22 Section K Parts Ratings IMPORTANT When calling or writing about the boiler PLEASE GIVE THE MODEL located on the boiler rating label AND THE C P NUMBER located next to the rating label WARNING DO NOT USE PETROLEUM BASED CLEANING OR SEALING COMPOUNDS IN BOILER SYSTEM SEVERE DAMAGE TO BOILER WILL OCCUR ooo m To install GV Boiler 1 READ Before Installing Boiler 2 SET UP i Boiler Preparation 3 CONNECT REFER TO FIGURE A Water Piping 1 relief valve 2 air vent expansion tank 3 from system return 4 to system supply Venting and Combustion Air 11 14 1 vent air intake termination 2 optional outside air intake 3 vent 4 condensate drain Gas Piping Field Wiring 4 COMPLETE Start Up Check Out Procedure FIGURE A UY a Pay attention to these terms DANGER indicates presence of hazard which will cause personal injury death or substan tial property damage if ignored indicates presence of hazard which can cause severe personal i
21. a ture and burner should reignite 15 Observed several operating cycles for proper op 9 Test ignition system safety device eration a Connect voltmeter to gas valve terminals 0 16 Set room thermostat to desired room tempera ture b Turn off manual gas valve c Set thermostat for heat 0 17 Completed Installation and Service Certificate d Ignitor will glow for approx 20 seconds Near below cd of 20 RAS T TAG will show at gas 18 Reviewed all instructions shipped with this boiler valve for approx 6 seconds and then return to with owner or maintenance person returned to OVAC envelope and given to owner or placed in pocket e To restart system follow lighting instructions inside front panel in boiler on page 18 Installation and Service Certificate BOILER MODEL SERIES CP NUMBER DATE INSTALLED MEASURED BTU INPUT O Installation instructions have been followed D Check out sequence has been performed Above information is certified to be correct D Information received and left with owner maintenance person Installer Company Address Phone Installer s Signature SUGGESTED MINIMUM MAINTENANCE SCHEDULE Maintenance as outlined below can be performed by the owner Also refer to User s Manual for specific maintenance instructions Regular service by a qualified service agency and mainte nance must be performed to assure maximum boiler oper ating efficiency Beginning each h
22. ardness or low pH water conditions below 7 0 Repair ALL leaks Continual fresh makeup water will reduce boiler life Minerals can build up in sections reducing heat transfer overheating cast iron and causing section failure Freeze protection when used a Use antifreeze made especially for hydronic sys tems Inhibited propylene glycol is recommended DO NOT use undiluted antifreeze or automotive antifreeze b Determine quantity according to system water content Boiler water content is listed on back page c Follow antifreeze manufacturer s instructions d 5096 solution provides maximum protection to about 30 F e Local codes may require back flow preventer or actual disconnect from city water supply FILL THE SYSTEM 1 2 Close manual and automatic air vents and drain cock Fill to correct system pressure Correct pressure will vary with each application Normal cold water fill pressure for residential system is 12 psi Open automatic air vent two turns Slowly feed water to boiler a Starting on the lowest floor open air vents one at a time until water squirts out Close vent b Repeat with remaining vents Close manual water feed valve when correct boiler pressure is reached Section G Start Up PLACE IN OPERATION 1 Verify boiler is filled with water 2 Follow lighting instructions on page 18 3 Check system piping for leaks If found repair imme
23. chimney See Figure 15 b through roof flashing jacket or thimble See Fig ure 16 e vent may pass through floor inside wall or concealed space when installed according to vent manufacturer s instructions enclo sure must be constructed of materials speci fied in those instructions 14 SEAL ALL CONNECTIONS WITH SIUCONE SEALANT PITCH UP A610ALG TYPICAL VENTING THOUGH THE ROOF FIGURE 16 MAINTAIN MINIMUM ONE INCH CLEARANCE from combustible materials to vent pipe Check all vent joints and seams for gas tight seal Repair if leaking Support piping a horizontal runs at least every 5 feet Canada b every 3 feet vertical runs use braces e under elbow or pipe near elbow e every 5 feet Canada every 3 feet Maintain 1 minimum clearance from combustible materials to vent pipe V eges 9 USE WRENCH TO HOLD PIPING Qo A710ALG GAS PIPING INSTALLATION FIGURE 17 Refer to Figure 17 to pipe gas Use wrench to hold factory installed gas piping nipple 2 Support piping with hangers not by boiler or its acces sories 3 Purge all air from supply piping 4 Check factory installed piping and field installed piping for leaks use BUBBLE TEST DO NOT check for gas leaks with an open flame USE BUBBLE TEST b Close manual main shut off valve during any pressure test ing at less than 13 W C c Di
24. diately 4 Ventair from system Repeat steps 4 and 5 under Fill the System Air in system can interfere with water circulation and cause improper heat distribution 5 Ifboiler fails to start check for a Loose connections blown fuse or service switch off b High limit switch set below boiler water tempera ture c Thermostat set below room temperature d Gas not turned on at meter or boiler e Incoming as pressure less than 4 W C f If above fails to correct problem refer to Gas Control Supplement INSPECT VENTING SYSTEM l Check for gas tight seal at all vent pipe connections CHECK BURNER FLAME AND IGNITOR GLOW 1 OBSERVATION PORT ABIOALG SEEING BURNER FLAME OR IGNITOR GLOW THROUGH OBSERVATION PORT FIGURE 19 Look through observation port in blower housing a ignitor glow is seen as yellow orange b flame is seen as round blue dot 7 FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of 1 A This appliance does not have a pilot It is equipped with an if you cannot reach your gas supplier call the fire ignition device which automatically lights the burner Do not department try to light the burner by hand C Use only your hand to push in or turn the gas control knob B BEFORE OPERATING smell all around the appliance
25. eating season 1 2 10 11 12 Annual service call by qualified service agency Visually check top of vent ell for soot Call service man to clean Some sediment at bottom of vent ell is normal Visually inspect venting system for proper function deterioration or leakage Check that boiler area is free from combustible materials gasoline and other flammable vapors and liquids Check for and remove any obstruction to the flow of combustion or ventilation air to boiler Follow Place in Operation page 17 Visually inspect burner flame and ignitor glow page 17 Check operation of safety devices Refer to manufac turer s instructions Follow oil lubricating instructions on circulator Over oiling will damage circulator Water lubricated circulators do not need oiling Visually inspect condensate drain hose for proper operation or deterioration Check for plugged con densate drain by checking for 1 or more inches of water in vent ell Check operation of mixing valve On cold start up return piping between mixing valve and circulator inside boiler will feel warmer than return piping out side jacket from system To avoid potential of severe burn DO NOT rest hands on or grasp pipes Use a light touch return piping will heat up quickly If mixing valve does not seem to be working the spring and thermostat may need to be replaced Call a qualified service technician Open jacket
26. ed combustion air spraycans containing chloro fluorocarbons permanent wave solutions chlorinated waxes cleaners chlorine based swimming pool chemicals calcium chloride used for thawing sodium chloride used for water softening refrigerant leaks paint or varnish removers hydrochloric acid muriatic acid cements and glues anti static fabric softeners used in clothes dryers chloride type bleaches detergents and cleaning solvents found in household laundry rooms adhesives used to fasten building products and other similar products Areas causing contaminate combustion air dry cleaning laundry areas and establishments b metal fabrication plants c beauty shops d refrigeration repair shops e f 5 h 1 j rem ne ao op 2 photo processing plants auto body shops plastic manufacturing plants furniture refinishing areas and establishments new build construction remodeling areas WARNING Check for areas and products as WARNING listed above before installing boiler If found e remove products permanently OR e provide outside combustion air 22 mmm Section J Appendix WHEN REMOVING BOILER FROM COMMON VENT ING SYSTEM At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in opera tion while the other appliances remaining connected to the common venting system are not
27. ers to common vent 4 Do not wrap or insulate vent pipe and fittings 5 Refer to vent locations page 5 6 Use DOW 732 or equivalent silicone sealant FOLLOW VENT COMBUSITON AIR PROCEDURE 1 Choose vent combustion air method thru sidewall with W M termination page 12 Uses either inside or outside combustion air thru sidewall with vent coupling termination page 13 Uses inside combustion air only e thru unused chimney as raceway page 14 Uses inside combustion air only e thru roof page 14 Uses inside combustion air only 2 Do not exceed limits in Table III for piping lengths and number of elbows Longer vent runs will slightly reduce boiler input See Appendix page 22 Table III Venting System Length Total No of Elbows o 2 s 4 5 e 7 8 GV 3 thru 5 70 GV 6 601 50 401 301 201 101 Note also use Table for outside air piping 9 3 Support piping a horizontal runs at least every 5 feet Canada every 3 feet b vertical runs use braces e under elbow or pipe near elbow every 5 feet Canada every 3 feet 4 To make non metallic vent joints a insert pipe in fitting and mark insertion point b remove pipe and spread silicone sealant inside marked area c re insert pipe in fitting and twist turn to ensure proper seal 5 Follow items listed below to avoid personal injury or property dam age a Cut non me
28. igure 5 ee Additional Ex Trol Tank Required for Additional Ex Trol Additional Ex Trol One Pipe Systems with Tank s Required for Tank s Required for Convector Baseboard Cast Iron Baseboard Cast Iron Radiators Table II Expansion Tank Sizing Standard Fill Trol Tank Adequate for Series Loop Boiler Piping Systems with Size Convector Baseboard cvs No19 NS Nois GV 4 109 5 X No 5 3 f GV 5 19 5 5 30 110 5 3 Tank selections based 220 F average system water temperature Systems with unusually large volumes of water may require additional expansion capability oe mmm PIPING SINGLE ZONE WITH CLOSED TYPE TANK FROM SYSTEM CLOSED TYPE RETURN FROM ADDITIONAL ZONES SEE NOTE PRV CHECK VALVE PIPING WATER FILL ISOLATION VALVE TO SYSTEM OR ADDITIONAL NOTE SEE PAGE 9 ZONES SEE NOTE FOR MULTIPLE ZONING PIPING WITH CLOSED TYPE EXPANSION TANK FIGURE 6 1 Pipe properly see Figure 6 to avoid improper operation and damage to boiler or building 2 Ifsystem is to comply with ASME codes an additional high temperature limit is needed Purchase and install in To System piping between boiler and isolation valve 3 Install relief valve in tapping on top of back section Relief valve discharge piping mus
29. in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition c Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common vent ing system are located and other spaces of the build ing Turn on clothes dryers and any appliances not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Fol low the lighting instructions Adjust thermostat so appliance will operate continuously e Test for spillage at draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe f After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use Any improper operation of common venting system should be corrected so the installation conforms with the
30. in slightly Do not force pushed in slightly Do not force 6 Wait five 5 minutes to clear out any gas If you then smell 6 Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above If you STOP Follow B in the safety information above If you don t smell gas go to next step don t smell gas go to next step 7 Depress and move selector arm right W to ON 7 Turn gas control knob counterclockwise to ON Turn on all electric power to the appliance Set thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier Replace control access panel TO TURN OFF GAS TO APPLIANCE Set the thermostat to lowest setting 3 To turn boiler OFF follow 5 in Operating Instructions above that corresponds with your valve 2 Turn off all electric power to the appliance if service is to be performed 4 Replace control access panel 8 Section Check Out Procedure 9 Check off steps as completed 10 High limit control set to design temperature re 1 Boiler and heat distribution units filled with water quirements of system Maximum high limit set 0 2 Automatic air vent if used open two full turns ting 220 F during venting pr
31. njury death or substantial property damage if ignored WARNING indicates presence of hazard which will or can cause minor personal injury or property damage if ignored CAUTION indicates special instructions on installa tion operation or maintenance which are important but not related to personal injury hazards NOTICE Section A Before Installing Boiler INSTALLATIONS MUST FOLLOW THESE CODES e local state provincial and national codes laws regulations and ordinances National Fuel Gas Code ANSI Z223 1 latest edition e Standard for Controls and Safety Devices for Auto matically Fired Boilers ANSI ASME CSD 1 when required National Electrical Code For Canada only CAN CGA B149 1 and 2 Installa tion Code and C S A C22 1 Part 1 Gas manifold and controls met safe lighting and other per formance criteria when boiler underwent tests specified in ANSI Z21 13 latest edition PROVIDE CLEARANCES AROUND BOILER CLEARANCES FOR EASY SERVICING FIGURE 1 4 DOOR W FRESH AIR OPENINGS 1 CLEARANCE N _ FRESH AIR OPENINGS 27 SIDE VIEW MINIMUM CLEARANCES FOR TIGHT SPACES FIGURE 2 Provide screwdriver clearance for removal of jacket screws If not unions and shut off valves should be installed in system so boiler can be moved for servicing PROPERLY LOCATE VENT TERMINATION VINTATA Give special attention to location of vent to avoid possibility of
32. ocedure O 11 For multiple zones flow adjusted so it is about the O 3 Air purged from system same in each zone 4 Air purged from gas piping Piping checked for 0 12 Thermostat heat anticipator if available set leaks properly Refer to Wiring page 16 5 Followed lighting instructions on page 18 for proper 13 Boiler cycled with thermostat Raise to highest start up setting and verify boiler goes through normal 0 6 Is burner flame or ignitor glow visible Refer to start up cycle Lower to lowest setting and verify Check Burner Flame and Ignitor Glow p 17 boiler goes off 0 7 Test safety controls If boiler is equipped with a low 0 14 Measure natural gas input water cut off or additonal safety controls test for a Operate boiler 10 minutes operation as outlined by manufacturer Burner b Turn off other appliances should be operating and should go off when con c At natural gas meter measure time in sec trols are tested When safety devices are restored onds required to use on cubic foot of gas burners should reignite d Calculate gas input 8 Test limit control While burner is operating move 3600 X 1000 Btuh indicator on high limit control below actual boiler number seconds from step C water temperature Blower and burner should go e Btuh calculated should approximate input off while circulator continues to operate Raise ratin d 5 rating label setting on limit control above boiler water temper
33. of Energy DOE VENT BOILER WATER SEASONAL COMBUSTION AIR CONTENT EFFICIENCY 95 DIAMETER IN Ratings also referred to as AGA CGA Output e Net Be ratings ore based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pick up Ratings ore based on a piping and pick up atiowance of 1 15 An additional allowance should be made for unusual piping and pick up loads Boilers are tested for 50 ibs working pressure GV boliers are not available for millivolt systems DIMENSIONS 3 4 NPT RELIEF VALVE OUTLET 1 NPT SUPPLY 1 2 NPT TO EXPANSION idi 149 16 10 13 16 3 4 CONDENSATE DRAIN 3 DIA VENT piping from meter to be sized according to focal utility requirements STANDARD EQUIPMENT Factory fire Test insulated Steel Jacket Cast Iron Sections with Built in Air Separator Steel Base Microprocessor Based Control Module with indicator Lights Blower Assembly with Observation Port Gas Air Manifold Aseembly Gas Air Orifice Plate for Natural Gas separate plate furnished for conversion to propane Stainless Steel Burner Cone and Ring Assembly Negative Regulation Gas Valve Hot Surface Ignition System Ak Pressure Switch Circulator 1 inch ali sizes Mixing Valve m WEIL Me LAI N Michigan City Indiana 46360 A Division of The Marley Company In Canada Marley Fluid Systems 126 East Dr Brampton Ontario L6T 1
34. rops of S A E 20 motor oil in 2 blower motor oil cups Replace control tray and restore power to boiler Do not use common universal household oils End of each heating season annual shut down procedure 1 2 Follow Turn Off Gas To Appliance instructions page 18 DO NOT drain system unless exposure to freezing temperatures will occur DO NOT drain system if antifreeze is used CLEANING BOILER HEATING SURFACES The following service procedures must be performed ONLY by a qualified service agency Boller owner should not attempt these procedures If you find soot in top of vent ell some sediment in bottom of vent ell is normal remove blower assem bly and clean inside boiler by spraying water into chamber Drain through condensate hose Also check burner replace if damaged check gas valve opera tion and negative outlet pressure replace if not okay gas valve is not adjustable check blower wheel operation If you find rust deposits in vent ell check mixing valve and clean boiler as above WARNING DO NOT DISASSEMBLE BLOWER HOUSING A FIRE OR EXPLOSION CAUSING SEVERE PERSONAL po INJURY OR PROPERTY DAMAGE CAN RESULT BLOWER on IF YOU SUSPECT A PROBLEM MOTOR WIRING A REPLACE BLOWER HARNESS x S A HOUSING PS EN NN N gt M Se o V M N K N BURNER S M RING ASSEMBLY a BLOWER Q SUPPORT d
35. sconnect boiler and gas valve from gas supply piping during any pressure testing greater than 13 W C 5 Use pipe dope compatible with propane gases Apply sparingly only to male pipe ends Section E Gas Piping Natural Gas Table IV Pipe Delivery Schedule Capacity of Pipe in Cubic Feet of Gas Per Hour 1 PA 1 Us Length of Pipe in Feet 7 gt based 0 60 Specific Gravity 0 30 W C pressure drop NOTE For additional piping schedules see ANSI 2223 1 1 Refer to Table IV for pipe length and diameter Base on rated boiler input divided by 1000 to obtain cubic feet per hour 2 Inlet pressure at gas valve inlet maximum 13 W C minimum 4 W C 3 Install 10096 lock up gas pressure regulator in supply line if inlet pressure exceeds 13 W C Adjust for 13 W C maximum Propane Gas 1 Boiler can be converted easily with propane conver sion kit supplied 2 Contact gas supplier to size pipes tanks and 10096 lock up pressure regulator 3 Adjustregulator provided by gas supplier for 13 W C maximum pressure 4 Inlet pressure at gas valve inlet maximum 13 W C minimum 4 W C 5 PROVIDED HIGH VOLTAGE FACTORY WIRING LOW VOLTAGE FACTORY WIRING HIGH VOLTAGE FIELD WIRING LOW VOLTAGE FIELD WIRING Section F Field Wiring SERVICE SWITCH THERMOSTAT FIELD WIRING DIAGRAM FIGURE 18 INSTALLATIONS MUST FOLLOW THESE CODES
36. t be piped near floor close to floor drain to eliminate po tential of severe burns Do not pipe to any area where freezing could occur 4 ASME requires a low water cut off device when boiler is installed above radiation level or by certain state or local codes or insurance companies Use low water cut off designed for water installations Electrode probe type is recommended Purchase and install in tee in supply piping above boiler 5 Connect tank from tapping shown in Figure 6 to ex pansion tank Use NPT piping Pitch any horizon tal piping up towards tank 1 per 5 feet of piping 6 Use backflow check valve where required by local codes USE WITH REFRIGERATION SYSTEM BALANCING VALVE RETURN CHECK VALVE STRAINER WATER CHILLER HEATING SHUT OFF BOILER SUPPL Y CIRCULATOR LX ISOLATION VALVE USE WITH REFRIGERATION SYSTEM FIGURE 7 1 Install boiler so that chilled medium is piped in parallel with heating boiler Use appropriate valves to prevent chilled medium from entering boiler Consult I B R In stallation and Piping Guides 2 If boiler is connected to heating coils located in air han dling units where they can be exposed to refrigerated air use flow control valves or other automatic means to prevent gravity circulation during cooling cycle PIPING MULTIPLE ZONES SUPPLY RETURN ADDITIONAL ZONE2 ZONE 1 ZONE 1 ZONE2 ADDITIONAL ZO
37. t for direct outside air through horizontal duct 3 All duct must be same size as connected opening with minimum dimensions of 3 x 3 or 9 total sq inches of area 4 Other size duct must comply with local codes e ANSI Z223 1 requires boiler combustion air open ing at least 18 above the floor for garage installa tion LAY A FOUNDATION IF NEEDED Table 1 Minimum Boiler Foundation Size WA RAR RRR 1 Approved for use combusible flooring but must NEVER BE INSTALLED ON CARPETING 2 Use level concrete slab or solid brick pad if floor can become flooded e non level conditions exist e high profile condensate pump is used foundation thickness may vary depending on type of pump installed See page 11 for details oe m Section B Boiler Preparation lt i HOW TO PLACE BOILER MAKE HYDROSTATIC PRESSURE TEST 3 4 PLUG BY OTHERS BASE RAIL LEG HOSE BIB FILL CONNECTION BY OTHERS BLEED TO DRAIN VALVE VALVE OTHERS 1 PLUG OTHERS PPLE BOILER SET UP FOR HYDROSTATIC PRESSURE TEST FIGURE 4 Pressure test before attaching water or gas piping except POSITIONING BOILER ON SITE as noted below or electrical supply FIGURE 3 CAUTION Leaks must be repaired at once to prevent damage tothe boiler NEVER use petroleum based stop leak compounds or leakage between sections will occur 1
38. tallic vent pipe with fine toothed hack saw 34 teeth per inch b Do not use non metallic vent pipe or fittings that are cracked or damaged c Donot use non metallic vent fittings if they are cut or altered Use only those fittings listed on page 25 d Do not drill holes or use screws or rivets in non metallic vent pipe or fittings 6 To make metallic vent joints a Point crimped ends of pipe towards boiler for good condensate drain back to boiler b Do not install seams of vent pipe on bottom of runs C Seal all joints and seams with silicone sealant 5 8 I D TUBING PROVIDED BY OTHERS CONDENSATE TUBING INSTALLATION FIGURE 12 7 See Figure 12 to install condensate tubing provided by others Use condensate pump if floor drain is not lower than condensate drain on boiler If required e use a low profile pump OR e set boiler on pad to allow gravity flow to pump Size pump in gal hr boiler model 0 78 GV 3 1 17 GV 4 1 56 GV 5 1 95 GV 6 Refer to pump manu facturer s instructions Drain to non freezing area VENTING THROUGH SIDEWALL USING W M VENT AIR INTAKE TERMINATION INSTALL TERMINATION IN ANY ORIENTATION SEAL ALL PITCH UP 1 4 PER FOOT VENTING THROUGH SIDEWALL WITH W M VENT AIR INTAKE TERMINATION FIGURE 13 OUTSIDE PLATE SPACERS TO SUPPORT VENT IN SLEEVE SEAL ALL CONNECTIONS WITH SILICONE SEALANT SIDE VIEW COMBUSTIBLE SIDEWA
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