Weil-McLain 550-141-850/0599, GOLD DV WATER BOILER Ib Prepare boiler location codes & altitude

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• Installation • Start-Up • Parts • Maintenance

Ib Prepare boiler location — codes & altitude

Installations must follow these codes:

•Local, state, provincial, and national codes, laws, regulations and ordinances.

•National Fuel Gas Code, ANSI Z223.1- latest edition.

•Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required.

•National Electrical Code.

•For Canada only: CAN/CGA B149.1 or B149.2 Installation Code and C.S.A. C22.1 Canadian Electrical Code Part 1 and any local codes.

High altitude installations

The GV boiler gas manifold and controls met safe lighting and other performance criteria when boiler underwent tests specified in ANSI Z21.13 — latest edition.

GV boiler controls automatically reduce input with increasing altitude. See Table 1 for estimated input at altitude as a percentage of sea level input. Multiply the boiler sea level input by this percentage to obtain the estimated high altitude input. Note that the length of the venting system will also have a minor impact on input. Refer to the vent supplement for further information.

No modifications to the boiler should be necessary for installations up to 5,500 feet above sea level. For higher elevations, the air pressure switch must be changed to a special high altitude switch. Refer to the high altitude kit instructions, manual Section IId. Note that the gas valve outlet pressure must be checked (and adjusted if necessary) in accordance with manual Section VIIf.

	Table 1		Altitude	% Sea level input
			(feet)	% Sea level input
	Estimated GV input at altitude		(feet)

			1,000	97
			1,000	97

			2,000	93
			3,000	90

			4,000	87
			5,000	83

			5,500	82
			6,000	80

			7,000	77
			8,000	74

			9,000	72
			10,000	69

At altitudes above 5,500 feet, GV boilers can be sidewall vented only when using direct vent (ducted combustion air). GV boilers can be vertically vented in any of the configurations shown in the vent supplements. Refer to vent supplements for more detail.

Part number 550-141-850/0699

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Contents Gold GV How it works Gold GV Water boiler Series Please read before proceeding Hazard definitions Installer UserWhen servicing boiler Boiler operationBoiler water Contents Contents Overview of this section Ia Prepare boiler location overviewIb Prepare boiler location codes & altitude Installations must follow these codesClearance options Ic Prepare boiler location clearancesLarge space Small spacePrecautions Residential garage installationFlooring and foundation FlooringId Prepare boiler location vent system Removing from existing ventGV 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 IIc Prepare boiler orifice plate Plate installationNatural gas PropaneBottom 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 Perform hydrostatic pressure test IIf Prepare boiler pressure testPrepare boiler for test Fig Fill and pressure testPiping connections for hydrostatic test For heating system with See pages 27 30 IIIa Water piping overviewIIIb Water piping relief valve Install relief valveSupply & return connections IIIc Water piping boiler connectionsAir separator Expansion tankPiping 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 Outdoor reset control IIIh Water piping multi-zone radiant systemMulti-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 Connecting gas supply piping to boiler Gas pipingPropane Gas Feet Electrical installation must comply with VI Field wiringWiring connections ThermostatsField wiring Factory wiring VIIa Start-up overview Freeze protection when usedVIIb Start-up preparation Verify water chemistryVerify gas/air orifice plate VIIb Start-up preparationCheck for gas leaks Fill the system with waterVIId Start-up to operate boiler VIIc Start-up read SectionPerform final checks before starting boiler Start the boilerVIIe Start-up if boiler doesn’t start VIId Start-up operate boilerConnect and adjust manometer VIIf Start-up altitude over 5,500 feet onlyCheck 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-upcontExpansion 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 Checking the air pressure switch XIc Troubleshooting air pressure switchBlower Housing XId Troubleshooting servicing tipsIgniter Gas ValveControl 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