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

Page 71

•Installation • Start-Up • Parts • Maintenance

Figure 34 GCM (control module) harness plug receptacle and indicator light locations.

	White		White	White
	120 VAC N		120 VAC N	120 VAC N
	Green	White	Green	Green
	Green	120 VAC N	Green	Green
	Ground	120 VAC N	Ground	Ground
	Black	Green	Black	Black
	120 VAC H	Ground	120 VAC H	120 VAC H
		Black	to System	to Bypass
		120 VAC H	to System	to Bypass
		120 VAC H	circulator	circulator
			circulator	circulator
			(long harness)	(short harness)
	120 VAC IN			120 VAC
				to circulators
		120 VAC to
		blower motor		Red wires to
				pressure switch
	White
	120 VAC N
				Blue wires to
	Black			gas valve
	Black
	120 VAC H	Yellow wires
		to limit control
		and block temp
		switch

	120 VAC to	Black wires to
	transformer
		thermostat circuit

POWER

TSTAT CIRC

LIMIT

PRES SWITCH

FLAME

Indicator lights

24 VAC control

circuits

120 VAC IN

120 VAC to transformer

120 VAC to blower motor

120 VAC to circulators

24 VAC control circuits

water temp sensor

24 VAC from transformer

120 VAC to igniter

Black leads to water

temperature sensor

water temp

sensor

24 VAC

Brown	Red

24 VAC from transformer

120VACN		120VACH
	White		Black

85051120 VAC to igniter

Part number 550-141-850/0699

71

Image 71

Contents Gold GV How it works Gold GV Water boiler Series Please read before proceeding Hazard definitions Installer UserBoiler water When servicing boilerBoiler operation 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 foundationGV special vent system Id Prepare boiler location vent systemRemoving from existing vent 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 Multi-zone radiant heating system piping Outdoor reset controlIIIh Water piping multi-zone radiant system 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 Propane Gas Connecting gas supply piping to boilerGas piping 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 boilerCheck Gas Control Set Point Connect and adjust manometerVIIf Start-up altitude over 5,500 feet only 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-upcontIgniter 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 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