Weil-McLain GOLD DV WATER BOILER, 550-141-850/0599 manual Contents

Page 6

GOLD GV Water boiler series 3 — manual

 

 

Contents

 

 

 

Contents

Summary

Pages

 

 

 

 

I.

Prepare boiler location

• Verify code compliance.

8 – 15

 

 

Check for high altitude requirements.

 

 

 

Provide required clearances and accessibility.

 

 

 

Plan vent and combustion air provisions.

 

 

 

Check existing common vents to be sure they will work when

 

 

 

old boiler is removed from system.

 

 

 

 

 

II.

Prepare boiler

Leave boiler on its skid until preparation complete.

16 – 25

 

 

Install vent starter tee.

 

 

 

Inspect/replace if necessary the gas/air orifice.

 

 

 

Install high altitude kit (over 5,500 feet).

 

 

 

Place boiler in position.

 

 

 

Hydrostatically test boiler.

 

 

 

 

III. Water piping

Select system type from navigation table on page 26, cover-

26 – 36

 

 

ing baseboard systems, radiator systems, radiant heating

 

 

 

systems, heat pump systems, snow melt systems and water

 

 

 

chiller systems.

 

 

 

Review boiler connections pages 28 – 29, including instal-

 

 

 

lation of air separator and expansion tank.

 

 

 

Review general system information, page 30.

 

 

 

Obtain any system components needed but not on hand at

 

 

 

the job site.

 

 

 

Install relief valve and discharge piping.

 

 

 

Connect system piping.

 

 

 

Install low water cutoff and additional limit control, if

 

 

 

required.

 

 

 

 

 

IV.

Venting and combustion air

Refer to Vent supplements included with boiler

37

 

 

 

 

V.

Gas piping

Connecting gas supply, including need for pipe supports.

38 – 39

 

 

Natural gas boilers — gas line sizing (for 0.3" w.c. drop).

 

 

 

Propane boilers — refer to gas supplier.

 

 

 

 

 

VI.

Field wiring

Code compliances.

40 – 41

 

 

Wiring must be N.E.C. Class 1.

 

 

 

Thermostat connections.

 

 

 

Junction box installation.

 

 

 

Field wiring diagram.

 

 

 

 

 

6

 

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
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