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

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• Installation • Start-Up • Parts • Maintenance

Contents

	Contents		Summary	Pages
	Contents		Summary	Pages

	VII. Start-up		• Determine water treatment needs, if any.	42 – 47
			Obtain correct antifreeze if freeze protection required.
			Check for gas leaks (have propane odorant verified by supplier).
			Fill system and purge air.
			Read Operating instructions, section IX, then start boiler.
			Check all piping and verify leak-free.
			Check gas valve outlet pressure (altitudes over 5,500 feet).

	VIII.Check-out procedure		Complete checklist and fill out certificate.	48 – 49

	IX.	Operation	GCM (control module) indicator lights and sequence of opera-	50 – 55
			tion.
			Ladder wiring diagram (page 52).
			Schematic wiring diagram (page 53).
			Lighting instruction sheet — boiler with Robertshaw 7200DERN
			gas valve (page 54).
			Lighting instruction sheet — boiler with White-Rodgers 36E gas
			valve (page 55).

	X.	Service and maintenance	Service/maintenance schedule table (page 57).	56 – 65
			Detailed instructions for annual start-up and service.
			Special procedures for condensate drain line check valve (page
			63, if needed) and cleaning boiler heating surfaces (page 64).

	XI.	Troubleshooting	Troubleshooting procedures (page 67).	66 – 81
			Checking air pressure switch (page 68).
			Servicing tips and precautions — Igniter, gas valve and blower
			housing (page 69).
			Servicing tips and precautions plus indicator lights and lockout
			modes of GCM (control module) (page 70).
			Common problems and solutions (pages 72 and 73).
			Troubleshooting based on GCM indicator lights (pages 74 – 81).

	XII. Replacement parts		Accessory bag assembly shipped with boiler (page 83).	82 – 93
			Section assembly parts (page 84).
			Jacket assembly parts (page 86).
			Blower assembly parts (page 88).
			Trim assembly parts (page 90).
			Interior panel parts (page 92).

	XIII.Dimensions and ratings		Dimensional drawing and boiler rating table.	94 – 95

	Part number 550-141-850/0699			7

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Contents Gold GV How it works Gold GV Water boiler Series Please read before proceeding Hazard definitions Installer UserBoiler operation When servicing boilerBoiler water Contents Contents Overview of this section Ia Prepare boiler location overviewIb Prepare boiler location codes & altitude Installations must follow these codesSmall space Ic Prepare boiler location clearancesClearance options Large spaceFlooring Residential garage installationPrecautions Flooring and foundationRemoving from existing vent Id Prepare boiler location vent systemGV special vent system Air contamination Ie Prepare boiler location contaminationIf Prepare boiler location air openings GV in small space less than alone Special considerationsIIb Prepare boiler vent starter tee & drain IIa Prepare boiler overviewScrew hole Base rail Insert Cpvc elbow Propane Plate installationIIc Prepare boiler orifice plate Natural gasBottom side of boiler front section IId Prepare boiler high altitude kit When requiredWhite Hose Red Altitudes above 5,500 feet onlyIIe Prepare boiler place in position Rotate Fill and pressure test IIf Prepare boiler pressure testPerform hydrostatic pressure test Prepare boiler for test FigPiping connections for hydrostatic test For heating system with See pages 27 30 IIIa Water piping overviewIIIb Water piping relief valve Install relief valveExpansion tank IIIc Water piping boiler connectionsSupply & return connections Air separatorPiping closed Zoning with circulators IIId Water piping all systemsBaseboard system piping IIIe Water piping baseboard systemRadiator system piping IIIf Water piping radiator systemIIIg Water piping single-zone radiant or heat pump system IIIh Water piping multi-zone radiant system Outdoor reset controlMulti-zone radiant heating system piping Manual bypass valves for fixed temp operation only IIIi Water piping snow melt systemWater chiller systems IIIj Water piping water chiller systemsIV Venting and combustion air Gas piping Connecting gas supply piping to boilerPropane Gas Feet Thermostats VI Field wiringElectrical installation must comply with Wiring connectionsField wiring Factory wiring Verify water chemistry Freeze protection when usedVIIa Start-up overview VIIb Start-up preparationFill the system with water VIIb Start-up preparationVerify gas/air orifice plate Check for gas leaksStart the boiler VIIc Start-up read SectionVIId Start-up to operate boiler Perform final checks before starting boilerVIIe Start-up if boiler doesn’t start VIId Start-up operate boilerVIIf Start-up altitude over 5,500 feet only Connect and adjust manometerCheck Gas Control Set Point At Least Inches Check-out procedure checklist VIIIa Check-out procedure overviewVIIIb Check-out procedure checklist IXa Operation overview Shows the ladder wiring diagram for the GV series 3 boilerSteps IXb Operation sequenceLadder diagram legend IXb Operation wiring diagramsGCM IXc Operation lighting instructions For Your Safety Read Before OperatingWhite-Rodgers gas valve model 36E Xa Service and maintenance overview Service technician Xb Service and maintenance scheduleAnnual start-up only by qualified service technician Xc Service & maintenance annual start-upStart-up Annual start-up check/test Xc Service & maint. annual start-upcontGauges Expansion tankIgniter Boiler relief valve Annual start-up owner reviewReview with owner Condensate drain line Check valve assembly To remove the blower assembly Igniter XIa Troubleshooting overview Before troubleshooting XIb Troubleshooting proceduresCheck the following Checking the air pressure switch XIc Troubleshooting air pressure switchGas Valve XId Troubleshooting servicing tipsBlower Housing IgniterControl Module XIe Troubleshooting control modulePower Symptom Common Causes Possible Corrections XIf Troubleshooting common problemsSymptom Common Causes Possible Corrections Chart 1 Troubleshooting Power light status XIg Troubleshooting GCM lightsChart 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 Water trim bag assembly #1 XIIb Replacement parts accessory bagDescription Model Weil-McLain Number Part number XIIc Replacement parts section assembly85041 422-200-228 XIId Replacement parts jacket assembly85042 382-200-340 XIIe Replacement parts Blower assemblyVent starter tee not included Description Weil-McLain Number Part number XIIf Replacement parts trim assembly85048 XIIg Replacement parts interior panel Interior panel Number Xiii Dimensions and ratingsDOE Gold GV Water boiler Series