Weil-McLain GOLD DV WATER BOILER manual IIc Prepare boiler orifice plate, Natural gas, Propane

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GOLD GV Water boiler series 3 — manual

IIc Prepare boiler — orifice plate

Check for correct orifice plate and replace if necessary

The correct orifice plate must be used. Failure to do so will result in severe personal injury, death or substantial property damage.

Natural gas:

For natural gas installations, inspect the silver gas/air orifice plate marking. It must be the same as the boiler size. If the orifice plate is stamped with another size, obtain the correct plate from your wholesaler. The boiler size is stamped where the “X” is shown in the plate stamping, Figure 5b.

Figure 5a

Check for correct orifice plate and replace if necessary.

Leave boiler on its back, on the skid, until inspection/ replacement is completed.

Propane:

For propane installations, replace the silver gas/air orifice plate with the red/white plate, per following instructions. Ensure the red/white plate boiler size is correct for the GV boiler being installed. The boiler size is stamped where the “X” is shown in the plate stamping, Figure 5b.

Also fill out the propane label in the conversion kit and attach to the left side of the jacket, above the gas inlet opening, as shown in Figure 5a.

Plate installation

Access the bottom of the blower housing as shown in Figure 5a.

To inspect the plate only, read the marking on the plate edge. It must read the same as the boiler size and fuel.

To replace the plate, using a manual screwdriver or nut driver, see Figure 5b:

1.Loosen screws 1 and 2 two full turns.

2.Remove screws 3 and 4.

3.Pull the gas/air orifice plate forward to remove it.

4.Slide in the new plate as shown in Figure 5b. The red side of a propane plate must go next to the blower housing as shown.

5.Replace screws 3 and 4. Tighten all four screws securely and uniformly. DO NOT overtighten. DO NOT exceed 40 inch-pounds torque.

6.Bend down plate label tab at score mark as shown in lower right corner of Figure 5b.

Remove jacket front panel to access the bottom side of the blower housing.

Complete the propane conversion label included with the conversion kit. Install label on jacket left side, as shown.

	Leave the boiler on its back, on the skid as
	shown, until you have checked the gas/air orifice
85004a	plate and replace it if necessary.

18	Part number 550-141-850/0699

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Contents Gold GV How it works Gold GV Water boiler Series Hazard definitions Installer User Please read before proceedingWhen servicing boiler Boiler operationBoiler water Contents Contents Ia Prepare boiler location overview Overview of this sectionInstallations must follow these codes Ib Prepare boiler location codes & altitudeLarge space Ic Prepare boiler location clearancesClearance options Small spaceFlooring and foundation Residential garage installationPrecautions FlooringId Prepare boiler location vent system Removing from existing ventGV special vent system Ie Prepare boiler location contamination Air contaminationIf Prepare boiler location air openings Special considerations GV in small space less than aloneIIa Prepare boiler overview IIb Prepare boiler vent starter tee & drainScrew hole Base rail Insert Cpvc elbow Natural gas Plate installationIIc Prepare boiler orifice plate PropaneBottom side of boiler front section When required IId Prepare boiler high altitude kitAltitudes above 5,500 feet only White Hose RedIIe Prepare boiler place in position Rotate Prepare boiler for test Fig IIf Prepare boiler pressure testPerform hydrostatic pressure test Fill and pressure testPiping connections for hydrostatic test IIIa Water piping overview For heating system with See pages 27 30Install relief valve IIIb Water piping relief valveAir separator IIIc Water piping boiler connectionsSupply & return connections Expansion tankPiping closed IIId Water piping all systems Zoning with circulatorsIIIe Water piping baseboard system Baseboard system pipingIIIf Water piping radiator system Radiator system pipingIIIg Water piping single-zone radiant or heat pump system Outdoor reset control IIIh Water piping multi-zone radiant systemMulti-zone radiant heating system piping IIIi Water piping snow melt system Manual bypass valves for fixed temp operation onlyIIIj Water piping water chiller systems Water chiller systemsIV Venting and combustion air Connecting gas supply piping to boiler Gas pipingPropane Gas Feet Wiring connections VI Field wiringElectrical installation must comply with ThermostatsField wiring Factory wiring VIIb Start-up preparation Freeze protection when usedVIIa Start-up overview Verify water chemistryCheck for gas leaks VIIb Start-up preparationVerify gas/air orifice plate Fill the system with waterPerform final checks before starting boiler VIIc Start-up read SectionVIId Start-up to operate boiler Start the boilerVIId Start-up operate boiler VIIe Start-up if boiler doesn’t startConnect and adjust manometer VIIf Start-up altitude over 5,500 feet onlyCheck Gas Control Set Point At Least Inches VIIIa Check-out procedure overview Check-out procedure checklistVIIIb Check-out procedure checklist Shows the ladder wiring diagram for the GV series 3 boiler IXa Operation overviewIXb Operation sequence StepsIXb Operation wiring diagrams Ladder diagram legendGCM For Your Safety Read Before Operating IXc Operation lighting instructionsWhite-Rodgers gas valve model 36E Xa Service and maintenance overview Xb Service and maintenance schedule Service technicianXc Service & maintenance annual start-up Annual start-up only by qualified service technicianStart-up Xc Service & maint. annual start-upcont Annual start-up check/testExpansion tank GaugesIgniter Annual start-up owner review Boiler relief valveReview with owner Condensate drain line Check valve assembly To remove the blower assembly Igniter XIa Troubleshooting overview XIb Troubleshooting procedures Before troubleshootingCheck the following XIc Troubleshooting air pressure switch Checking the air pressure switchIgniter XId Troubleshooting servicing tipsBlower Housing Gas ValveXIe Troubleshooting control module Control ModulePower XIf Troubleshooting common problems Symptom Common Causes Possible CorrectionsSymptom Common Causes Possible Corrections XIg Troubleshooting GCM lights Chart 1 Troubleshooting Power light statusChart 2 Tstat Circ & Power lights flashing Chart 3 Limit & Power lights flashing Chart 4 Pres Switch & Power lights flashing Chart 5 Flame & Power lights flashing Chart 6 Tstat Circ light flashing and Power light on steady Chart 7 Limit light flashing and Power light on steady Is thermostat circuit closed continuity across wires? XIIa Replacement parts overview XIIb Replacement parts accessory bag Water trim bag assembly #1XIIc Replacement parts section assembly Description Model Weil-McLain Number Part number85041 XIId Replacement parts jacket assembly 422-200-22885042 XIIe Replacement parts Blower assembly 382-200-340Vent starter tee not included XIIf Replacement parts trim assembly Description Weil-McLain Number Part number85048 XIIg Replacement parts interior panel Interior panel Xiii Dimensions and ratings NumberDOE Gold GV Water boiler Series