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GV100W BOILER
INSTALLATION & OPERATING INSTRUCTIONS
BOILER MAINTENANCE
WARNING: The ceramic combustion chamber in the burner box and its gasket contain crystalline silica. Wear a tightly fitted dust mask when servicing the burner and gently handle the burner and its gasket to prevent inhalation of airborne fibers. Crystalline silica fibers have been identified as carcinogenic, or possibly carcinogenic when inhaled.
CAUTION: Servicing, inspection and adjustment must be done by a trained technician in accordance with all applicable local and national codes.Verify proper operation after servicing. Improper servicing or adjustment can damage the boiler!
The boiler should be cleaned and inspected once a year, before each heating season. Use a soft brush and/or a vacuum cleaner to ensure that the burners and ignition components are free from dust, soot, dirt, corrosion or other deposits that would impair the boiler’s performance. Refer to page 22 for component identification.
Burner Removal
1.Close the manual shutoff valve in the gas supply line and turn off electrical power to the boiler.
2.Remove the front access panel.
3.Disconnect the gas supply, see FIG. NO. 8.
4.Where applicable, disconnect the wires and pilot tube from the gas valve.
5.Remove the two nuts holding the manifold assembly and remove the assembly.
6.Remove the top half of the burner support panel and the burners.
Burner Installation
1.Do not install damaged or badly corroded burners - replace them.
2.Insert the crimped end of each burner into the slot in the burner base rear panel.
3.Work the manifold assembly into position and start the two retaining nuts. Slide the top half of the burner support panel in place and tighten the nuts.
4.Reconnect all wires, tubing and anything else disconnected during the burner removal operation.
5.Complete the reassembly and follow the instructions in the BOILER OPERATION section of this manual.
Heat Exchanger Cleaning
Remove the burners to protect them from falling rust and scale by following the Burner Removal instructions.
1.Remove the vent pipe, front access and top panels.
2.Disconnect the inducer wires and carefully separate the inducer from the flue collector.
3.Remove the two flue collector retaining clips. Cut the RTV seal and remove the flue collector.
4.Clean the flue passages with a wire brush.
5.Vacuum out the burner base and clean and inspect the ignition system components. Damaged or badly corroded parts must be replaced.
6.Remove the old flue collector sealant and reseal the flue collector. Use Dow Corning #732 RTV or an equivalent silicone sealant. Install the flue collector retaining clips and screws.
7.Clean then reseal the inducer using Dow Corning #732 RTV or an equivalent silicone sealant before reattaching it to the flue collector.
8.Replace the top panel.
WARNING: The flue collector and inducer must be properly sealed. Allow the RTV sealant 24 hours to cure before using the boiler. Improper sealing could result in carbon monoxide poisoning!
9.Reconnect the inducer wires and the vent system.
10.Follow the Burner Installation procedure above.
11.Once the sealant has cured, fire the boiler to make sure that it operates properly.
Vent System
At least once a year the entire vent system must be thoroughly inspected for any signs of blockage, corrosion or leaks. Immediately replace any unsound vent system piping. Remove any foreign matter in or near the vent terminal or around the boiler that might obstruct the flow of combustion and ventilation air. Inspect the condensate trap, if installed, for blockage and clean if necessary. Every 3 to 6 months, lubricate the inducer motor using 2 drops of 20W non detergent motor oil in each oil port.
WARNING : Failure to properly inspect the vent system on a regular basis may leave problems undetected that can result in excessive levels of carbon monoxide which can cause severe personal injury or death!
