Weil-McLain GOLD DV WATER BOILER manuals
Household Appliance > Boiler
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Weil-McLain GOLD DV WATER BOILER Manual
96 pages 3.79 Mb
2 8 Ia10 IcClearance options:SIDE VIEW TOP VIEW Flooring Foundation 11 Flooring and foundationResidential garage installation Prepare boiler location vent systemVent system Vent termination and combustion air supply When removing a boiler from an existing common vent system: 12 IdGV special vent system Removing from existing vent Prepare boiler location contamination 13 Ie14 IfPrepare boiler location air openingsGV combustion air optionsUsing inside air non-direct vent Using outside air direct vent Sizing air openings GV with other appliancesGV direct vent large shared space GV inside air large shared space Single air opening optionGV direct vent large shared space single air opening GV inside air large shared space single air opening GV without other appliancesGV direct vent large space alone GV inside air large space alone GV in small space (less than Fig. 1) alone Special considerations 15 a db ca b c d Exhaust fans and air movers Motorized air dampers Prepare boiler overview Prepare boiler vent starter tee & drainIIbInstall vent starter tee as shown in Figure 4. Install condensate trap hose as shown in Figure 4. Install vent starter tee and condensate drain hose 16 IIa17 IIbPrepare boiler vent starter tee & drain (cont.)Figure 4 Install vent starter tee and condensate drain hose before placing boiler. 18 IIcPrepare boiler orifice plateNatural gas: Propane:Propane: Propane:Propane: Propane: Plate installation Check for correct orifice plate and replace if necessary Prepare boiler high altitude kitWhen requiredWhen required When requiredWhen required When required Obtain high altitude kit 20 IId22 IIePrepare boiler place in position Prepare boiler pressure testPerform hydrostatic pressure testPrepare boiler for test (Fig. 7) 24 IIf27 IIIbInstall relief valve Water piping boiler connectionsSupply & return connections Air separator Expansion tank 28 IIIc47 +-48 Check-out procedure overviewVIIIa Check-out procedure checklistVIIIb49 Check-out procedure checklist (cont.)VIIIbInstallation and service certificate 50 Operation overviewIXa51 Operation sequenceIXb52 Operation wiring diagramsIXbFigure 23 Ladder wiring diagramNotes Ladder diagram legend 53 GCMFigure 24 Schematic wiring diagram 54 Operation lighting instructionsIXc56 Service and maintenance overviewXa57 Service and maintenance scheduleXbService technicianTable 4 Service and maintenance schedules A - NNNUALInspect: Service: Start-up: Check/test: Review: 58 Service & maintenance annual start-upXcAnnual start-up only by qualified service technician inspectReported problems Boiler area Air openings Flue gas vent system (and air inlet piping) Boiler heating surfaces Water piping Condensate drain system 59 servicestart-upStart-up procedure Blower motor Oiled-bearing circulators Gas piping Cold fill and operating pressures Temperature mixing system 60 Service & maint. annual start-up (cont.)XcAir vents and air elimination Limit controls and cutoffs 61 Expansion tankGauges Igniter 62 Service & maint. annual start-up (cont.)XcReview with owner owner review 63 Service & maint. special proceduresXd Condensate drain line check valve kit64 Service & maint. special proced. (cont.)Xd Cleaning boiler heating surfacesTo clean heating surfaces To remove the blower assembly Replace blower assembly 66 Troubleshooting overviewXIa67 Troubleshooting proceduresXIb68 Troubleshooting air pressure switchXIcChecking the air pressure switchCheck switch pressure setting Troubleshooting air pressure reading Return to normal operation 69 Troubleshooting servicing tipsXIdIgniter Blower HousingRobertshaw Model 7200DERN-680 White-Rodgers Model 36E66-302 Gas Valve 70 Troubleshooting control moduleXIeControl ModuleNon-lockout light conditionsTSTAT CIRC light flashing alone LIMIT light flashing alone Troubleshooting the GCM Control indicator lights lockout modesPOWER light flashing alone POWER and TSTAT CIRC lights flashing POWER and LIMIT light flashing alternately POWER and PRES SWITCH lights flashing POWER and FLAME lights flashing 72 Troubleshooting common problemsXIfSymptom Common Causes Possible CorrectionsRapid cycling boiler turns on and off frequently Black water condition Frequent release of water through relief val ve Need to frequently add makeup water 73 Symptom Common Causes Possible CorrectionsPopping or percolating noise heard in boiler Metal flakes found in vent outlet or vent starter tee flueway corrosion Some radiators or baseboard units do not heat or are noisy 74 Troubleshooting GCM lightsXIgPOWER light off? POWER POWER POWER 24 VAC Figure 34, Item 7 Figure 34, Item 1 Troubleshooting CHART 1 light statusFigure 34, Item 2light flashing now? light... 75 CHART 2POWER Is boiler internal Bypass circulator operating? Figure 34, Item 4 & TSTAT CIRC lights flashingDoes the voltmeter indicate 120 VAC? Is return water temperature sensor clamped securely to the return pipe in the boiler? Did you find and correct a voltage across the two external thermostat circuit wires? Is harness ok? Does problem persist? 76 CHART 3POWER Does the ohmmeter indicate a shorted sensor (zero ohms)? Figure 34, Item 6 Figure 34, Item 5 & LIMIT lights flashingDoes the ohmmeter indicate a shorted wire harness (zero ohms)? Does limit control shut off gas correctly? 77 CHART 4PRES SWITCH & POWER Is purge light flashing? Does the voltmeter indicate Figure 34, Item 3 lights flashingDoes the ohmmeter indicate the switch is closed? Does blower motor operate? Does blower wheel turn freely by hand? Is blower wheel turning at speed of blower motor? Check condensate trap. Is there condensate present? Are vent or combustion air passages blocked? Does blower motor operate? 78 CHART 5FLAME & POWER across gas valve terminals? 24 VAC POWER FLAME POWER FLAME lights flashingDuring step 5 of sequence of operation (Figure 22), is there Are manual main shutoff valve and gas valve turned on? 79 CHART 6POWER Are both boiler internal circulators operating? light flashing and TSTAT CIRC Figure 34, Item 4Does the voltmeter indicate 120 VAC? light on steadyIs return water temperature sensor clamped securely to the return pipe in the boiler? Is harness ok? Is there a call for heat? Does LIMIT light quit flashing (and pipes begin to heat up)? 80 CHART 7POWER light flashing and LIMIT light on steadyFigure 34, Item 6Does LIMIT light still flash? 81 CHART 8POWER Are block switch contacts closed? Are limit switch contacts closed? Is Does voltmeter show 120 VAC across pins? Insufficient heat or no heat to system ( light on steady)Is thermostat circuit closed (continuity across wires)? Is vent or combustion air piping free of blockage? Figure 34, Item 4Is boiler System circulator operating? light on? Are limit switch contacts closed? Are block switch contacts closed? 82 Replacement parts overviewXIIa83 Replacement parts accessory bagXIIbTable 5 The parts below are shipped with the boiler in the accessory bag. Item number Description Model Weil-McLain part number 84 Replacement parts section assemblyXIIc86 Replacement parts jacket assemblyXIIdItem number Description Model Weil-McLain part number 88 Replacement parts Blower assemblyXIIeTable 8 Blower assemblypropane to natural natural to propane Item number Description Model Weil-McLain part number 90 Replacement parts trim assemblyXIIfItem number Description Weil-McLain part number 92 Replacement parts interior panelXIIg94 Dimensions and ratingsXIIIFigure 40 Dimension drawing (see dimension table on opposite page) L 95 L
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