Weil-McLain GOLD DV WATER BOILER, 550-141-850/0599 manual IXa Operation overview

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GOLD GV Water boiler series 3 — manual

IXa Operation — overview

Overview of this section

❏The GCM (control module) is equipped with five indicator lights, used to show normal and problem situations. See Figure 22 for the normal sequence of operation of the boiler and control, and the status of the lights at each stage. For explanation of the lockout conditions of the GCM lights, see manual Section X, Troubleshooting.

❏Figure 23 shows the ladder wiring diagram for the GV series 3 boiler.

❏Figure 24 is the schematic wiring diagram, showing the destination of each of the wire harnesses attached to the control module.

❏Figure 25 is the Lighting instruction sheet for boilers equipped with Robertshaw model 7200DERN valves.

❏Figure 26 is the Lighting instruction sheet for boilers equipped with White- Rodgers model 36E valves.

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Contents Gold GV How it works Gold GV Water boiler Series Hazard definitions Installer User Please read before proceedingBoiler water When servicing boilerBoiler operation 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 FlooringGV special vent system Id Prepare boiler location vent systemRemoving from existing vent 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 Multi-zone radiant heating system piping Outdoor reset controlIIIh Water piping multi-zone radiant system 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 Propane Gas Connecting gas supply piping to boilerGas piping 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 startCheck Gas Control Set Point Connect and adjust manometerVIIf Start-up altitude over 5,500 feet only 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/testIgniter Expansion tankGauges Review with owner Annual start-up owner reviewBoiler relief valve Condensate drain line Check valve assembly To remove the blower assembly Igniter XIa Troubleshooting overview Check the following XIb Troubleshooting proceduresBefore troubleshooting 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