Weil-McLain 588 Instruction Manual

®• Installation• Startup• Maintenance• PartsBoiler ManualGas-Fired Water Boilers This manual must only be used by a qualified heating installer/servic

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual10Figure 8 Air pressure switch mounting1 Interior panel top2 Jacket left si

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual100Dimensions and ratingsFigure 107 Dimension drawing (see Figure 108, page 1

Part number 550-142-054/0411101GV90+ gas-fired water boiler — Boiler ManualFigure 108 Boiler dimensional and physical data (see Figure 107, page 100)

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual102Dimensions and ratings (continued)Figure 110 Multiple GV90+ boilers — rati

Part number 550-142-054/0411103GV90+ gas-fired water boiler — Boiler ManualFigure 111 Engineering data — see page 101 for additional technical info

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual104NOTES

Part number 550-142-054/0411105GV90+ gas-fired water boiler — Boiler ManualNOTES (continued)

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual106NOTES

Part number 550-142-054/0411107GV90+ gas-fired water boiler — Boiler ManualHandling ceramic fiber and fiberglass materialsHANDLING CERAMIC FIBER MATERIA

GV90+ gas-fired water boiler — Boiler Manual108Installation and service certificateBoiler model __________________ Series __________ CP

Part number 550-142-054/041111GV90+ gas-fired water boiler — Boiler ManualFigure 10 Piping connections for hydrostatic testPerform hydrostatic pressu

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual12Install water pipingAir separatorInstall an air separator in the piping

Part number 550-142-054/041113GV90+ gas-fired water boiler — Boiler ManualInstall water piping (continued)Figure 13 Relief valve installation guideli

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual14Figure 14 Piping to single-zone system using diaphragm- or bladder-type exp

Part number 550-142-054/041115GV90+ gas-fired water boiler — Boiler ManualInstall water piping (continued)System water piping methods Most piping m

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual16Figure 17 Baseboard system — circulator zoningBaseboard system piping — CI

Part number 550-142-054/041117GV90+ gas-fired water boiler — Boiler ManualLegend 1 Isolation valves 2 Automatic air vent (with diaphragm-type exp

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual18Figure 20 Radiator system — zone-valve zoningFigure 21 Radiator system — c

Part number 550-142-054/041119GV90+ gas-fired water boiler — Boiler ManualFigure 22 Single-zone radiant heating or heat pump systemSingle-zone rad

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual21 Integrated boiler controlThe integrated boiler control (IBC) responds to s

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual20Figure 23 Auto system supply temp regulation — zone valve zoningFigure 24

Part number 550-142-054/041121GV90+ gas-fired water boiler — Boiler ManualFigure 25 Auto return temp regulation — circulator zoningPiping snow melt s

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual22Figure 27 Installing GV90+ boiler in system with water chillerWater chiller

Part number 550-142-054/041123GV90+ gas-fired water boiler — Boiler ManualMultiple boiler installationsPlacing multiple boilers1. Locate multiple boi

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual24Multiple boiler water pipingEasy-Fit® piping installation1. Main header and

Part number 550-142-054/041125GV90+ gas-fired water boiler — Boiler ManualMultiple boiler water piping (continued)Legend — Figure 32 1 Flow/check va

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual26Multiple boiler water piping (continued)Legend — Figure 33 1 Flow/check va

Part number 550-142-054/041127GV90+ gas-fired water boiler — Boiler ManualFigure 34 Piping layout — typical for multiple GV90+ boilers, with DHW stor

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual28Multiple boiler water piping (continued)Figure 35 Piping layout — typical f

Part number 550-142-054/041129GV90+ gas-fired water boiler — Boiler ManualVenting & air — general GV90+ boilers must be vented and supplied with

Part number 550-142-054/04113GV90+ gas-fired water boiler — Boiler ManualGV90+ Water Boiler

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual30Venting & air — general (continued)Provide combustion air: DIRECT VENT

Part number 550-142-054/041131GV90+ gas-fired water boiler — Boiler ManualVenting & air — general (continued)Figure 37 Combustion air manifold opt

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual32Venting & air — general (cont.)Figure 39 GV90+ venting and air piping —

Part number 550-142-054/041133GV90+ gas-fired water boiler — Boiler ManualVenting & air — general (cont.)Figure 40 Vent and air piping materials

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual34(a) For all sidewall horizontally-vented gas-fueled equipment installed

Part number 550-142-054/041135GV90+ gas-fired water boiler — Boiler ManualVent termination requirementsFigure 41 The vent termination must be located

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual36Figure 42 Combustion and ventilation air openings for GV90+ Direct Vent ins

Part number 550-142-054/041137GV90+ gas-fired water boiler — Boiler ManualDIRECT VENT — Sidewall with W-M vent/air plateAllowable vent/air pipe materi

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual38Figure 44 Multiple terminations — Weil-McLain vent/air plate — clearance fr

Part number 550-142-054/041139GV90+ gas-fired water boiler — Boiler ManualDIRECT VENT — Sidewall with separate pipesAllowable vent/air pipe materials

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual4How it works . . . . . . . . . . . . . .2GV90+ Water Boiler . .

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual40DIRECT VENT — Sidewall with separate pipes (continued) For multiple boiler

Part number 550-142-054/041141GV90+ gas-fired water boiler — Boiler ManualDIRECT VENT — Sidewall with 3” concentricAllowable vent/air pipe materials &

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual42DIRECT VENT — Sidewall with 3” concentric (continued)Figure 51 Termination

Part number 550-142-054/041143GV90+ gas-fired water boiler — Boiler ManualDIRECT VENT — Vertical with separate pipesAllowable vent/air pipe materials

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual44Figure 54 Terminations for multiple boilers Also maintain maximum cente

Part number 550-142-054/041145GV90+ gas-fired water boiler — Boiler ManualDIRECT VENT — Vertical with 3” concentricAllowable vent/air pipe materials &

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual46DIRECT VENT — Vertical with 3” concentric (continued)Mount concentric termin

Part number 550-142-054/041147GV90+ gas-fired water boiler — Boiler ManualConcentric termination assembly (sidewall or vertical)Figure 58 3” PVC conc

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual48Vent and air piping and boiler connectionsDIRECT EXHAUST & DIRECT VE

Part number 550-142-054/041149GV90+ gas-fired water boiler — Boiler ManualDIRECT EXHAUST — Boiler room air openingsSpecial considerationsTight constru

Part number 550-142-054/04115GV90+ gas-fired water boiler — Boiler Manual Failure to adhere to the guidelines on this page can result in severe pe

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual50DIRECT EXHAUST — Boiler room air openings (cont.)Figure 60 MINIMUM combusti

Part number 550-142-054/041151GV90+ gas-fired water boiler — Boiler ManualDIRECT EXHAUST — Sidewall DO NOT sidewall vent DIRECT EX-HAUST APPLICATIONS

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual52DIRECT EXHAUST — Sidewall (continued)Figure 62 DIRECT EXHAUST — Sidewall —

Part number 550-142-054/041153GV90+ gas-fired water boiler — Boiler ManualDIRECT EXHAUST — VerticalAllowable vent/air pipe materials & lengths Us

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual54Gas pipingConnecting gas supply piping Do not connect gas supply to boiler

Part number 550-142-054/041155GV90+ gas-fired water boiler — Boiler ManualFigure 65 Pipe capacity for 0.60 specific gravity natural gasGas pipe length

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual56Wiring For your safety, turn off electrical power supply at service entranc

Part number 550-142-054/041157GV90+ gas-fired water boiler — Boiler ManualFigure 68 Ladder wiring diagramWiring (continued)

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual58Figure 69 Schematic wiring diagramWiring (continued)

Part number 550-142-054/041159GV90+ gas-fired water boiler — Boiler ManualStart-up Eliminate all system leaks. Continual fresh makeup water will redu

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual6Figure 1 Estimated GV90+ input at altitudeAltitude (feet)% Sea level input1,

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual602. See Replacement parts at the end of this manual for Weil-McLain part num

Part number 550-142-054/041161GV90+ gas-fired water boiler — Boiler ManualStart-up (continued)3. Inject all of the inhibitor supplied with the boiler

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual62Start-up (continued)Figure 72 Check for igniter glow by looking into observ

Part number 550-142-054/041163GV90+ gas-fired water boiler — Boiler ManualFigure 73 Tools required for gas valve outlet pressure measurement1 U-tube

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual64Start-up (continued)Final checklistUse the checklist following to ensure boi

Part number 550-142-054/041165GV90+ gas-fired water boiler — Boiler ManualFigure 75 Integrated boiler control (IBC) sequence of operation — status li

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual66Figure 76 Operating instructionsStart-up (continued)

Part number 550-142-054/041167GV90+ gas-fired water boiler — Boiler ManualFigure 77 Service and maintenance schedulesService technician (see followin

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual68Annual start-upAddress reported problems1. Inspect any problems reported by

Part number 550-142-054/041169GV90+ gas-fired water boiler — Boiler ManualInspect expansion tank1. Expansion tanks provide space for water to move in

Part number 550-142-054/04117GV90+ gas-fired water boiler — Boiler ManualFoundationProvide a solid brick or concrete foundation pad if any of the foll

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual70Inspect recuperator1. Follow the procedure on page 73 to inspect the recupe

Part number 550-142-054/041171GV90+ gas-fired water boiler — Boiler ManualAnnual start-up (continued)Inspect boiler relief valve1. Inspect the relief

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual72Service & maintenanceFigure 81 Blower housing removal procedure1 Blowe

Part number 550-142-054/041173GV90+ gas-fired water boiler — Boiler ManualService & maintenance (continued)To clean the burner The burner may

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual74Removing/cleaning/re-installing the recuperatorDisconnect the vent pipe from

Part number 550-142-054/041175GV90+ gas-fired water boiler — Boiler ManualTroubleshootingVERIFY PROPER OPERATION AFTER SERVICING. Label all wires p

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual76Troubleshooting (continued)Figure 86 IgniterFigure 87 Gas valveFigure 88

Part number 550-142-054/041177GV90+ gas-fired water boiler — Boiler Manualc. Immediately disconnect the return temperature sensor plug from the IBC.d

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual78Figure 93 IBC harness plug receptacle and indicator light locationsTroubles

Part number 550-142-054/041179GV90+ gas-fired water boiler — Boiler ManualTroubleshooting (continued)Figure 94 Common causes and possible corrections

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual8Prepare the boiler (continued) Check orifice plate — replace if necessary Th

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual80Troubleshooting (continued)Figure 95 Common causes and possible corrections

Part number 550-142-054/041181GV90+ gas-fired water boiler — Boiler ManualTroubleshooting (continued)Boiler should now operate normally.Problem is wit

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual82Troubleshooting (continued)CHART 2 TSTAT CIRC & POWER lights flashingElec

Part number 550-142-054/041183GV90+ gas-fired water boiler — Boiler ManualTroubleshooting (continued)CHART 3 LIMIT & POWER lights flashingElectrica

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual84Troubleshooting (continued)CHART 4 PRESS SWITCH & POWER lights flashingEl

Part number 550-142-054/041185GV90+ gas-fired water boiler — Boiler ManualTroubleshooting (continued)CHART 5 FLAME & POWER lights flashingElectrica

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual86Troubleshooting (continued)CHART 6 TSTAT CIRC light flashing and POWER light

Part number 550-142-054/041187GV90+ gas-fired water boiler — Boiler ManualTroubleshooting (continued)CHART 7 LIMIT light flashing and POWER light on st

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual88CHART 8 Insufficient heat or no heat to system (POWER light on steady)Electri

Part number 550-142-054/041189GV90+ gas-fired water boiler — Boiler ManualReplacement parts Figure 96 Miscellaneous partsDescription Model Weil-McLai

Part number 550-142-054/04119GV90+ gas-fired water boiler — Boiler ManualPrepare the boiler (continued)Figure 7 Install condensate trapA In-line flue

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual90Replacement parts (continued)Figure 97 Section assemblyItemnumberDescriptio

Part number 550-142-054/041191GV90+ gas-fired water boiler — Boiler ManualFigure 98 Section assemblyReplacement parts (continued)

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual92Figure 99 Jacket assemblyItemnumberDescription Model Weil-McLainpart number

Part number 550-142-054/041193GV90+ gas-fired water boiler — Boiler ManualFigure 100 Jacket assemblyReplacement parts (continued)

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual94Figure 101 Blower assemblyItemnumberDescription Model Weil-McLainpart numbe

Part number 550-142-054/041195GV90+ gas-fired water boiler — Boiler ManualFigure 102 Blower assemblyReplacement parts (continued)

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual96Figure 103 Trim assemblyItemnumberDescription Weil-McLainpart number1 Syste

Part number 550-142-054/041197GV90+ gas-fired water boiler — Boiler ManualFigure 104 Trim assemblyReplacement parts (continued)

Part number 550-142-054/0411GV90+ gas-fired water boiler — Boiler Manual98Figure 105 Interior panelItemnumberDescription Weil-McLainpart number1 Inte

Part number 550-142-054/041199GV90+ gas-fired water boiler — Boiler ManualFigure 106 Interior panelReplacement parts (continued)