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

Contents

Main How it works . . . Installation Start-Up Parts Maintenance GOLD GV Water boiler Series 3 Hazard definitions Please read before proceeding Table of contents User Installer Please read before proceeding When servicing boiler Boiler operation Boiler water Contents Contents Summary Pages Contents Contents Summary Pages Ia Prepare boiler location overview Overview of this section Prepare boiler location codes & altitudeIb Installations must follow these codes: High altitude installations Large space Small space Ic Clearance options: SIDE VIEW TOP VIEW Flooring Flooring and foundation Residential garage installation Precautions Prepare boiler location vent system Vent system Id GV special vent system Removing from existing vent Prepare boiler location contamination Air contamination Ie If Prepare boiler location air openings GV combustion air options Using inside air non-direct vent Using outside air direct vent a d b c a b c IIa IIb Prepare boiler vent starter tee & drain (cont.) Figure 4 Install vent starter tee and condensate drain hose before placing boiler. IIc Prepare boiler orifice plate Natural gas: Propane:Propane: Propane:Propane: Propane: Bottom side of boiler front section Prepare boiler high altitude kit When requiredWhen required When requiredWhen required When required Obtain high altitude kit IId Install high altitude air pressure switch Check gas valve outlet pressure altitudes above 5,500 feet ONLY IIe Prepare boiler place in position Position boiler ROTATE Prepare boiler pressure test Perform hydrostatic pressure test Prepare boiler for test (Fig. 7) IIf Drain and remove fittings Page Water piping overviewIIIa Water piping relief valve IIIb Install relief valve Water piping boiler connections Supply & return connections Air separator IIIc Backflow preventer Page Water piping all systemsIIId Zoning with circulators Zoning with zone valves Additional components Water piping baseboard systemIIIe Baseboard system piping Water piping radiator systemIIIf Radiator system piping Water piping single-zone radiant or heat pump systemIIIg Water piping multi-zone radiant systemIIIh Multi-zone radiant heating system piping Outdoor reset control Water piping snow melt systemIIIi Piping snow melt systems or combination snow melt/ space heating systems Water piping water chiller systemsIIIj Water chiller systems Venting and combustion airIV Gas pipingV Connecting gas supply piping to boiler Natural Gas: Propane Gas: Manifold Gas pipe length (feet) Capacity of pipe for pipe size of: (Capacity in cubic feet gas per hour) ""1" 1" 1" Table 3 Pipe capacity for 0.60 specific gravity natural gas Field wiringVI Electrical installation must comply with: Wiring connections Thermostat(s) Junction Box (furnished) Page Start-up overviewVIIa Start-up preparationVIIb Verify water chemistry Freeze protection (when used) Start-up preparation (cont.)VIIb Verify gas/air orifice plate Check for gas leaks Fill the system with water Inspect system water piping Start-up read Section IXVIIc Boiler sequence of operation Start-up to operate boilerVIId Perform final checks before starting boiler Start the boiler Start-up if boiler doesnt start . . .VIIe Start-up operate boiler (cont.)VIId Check for: Start-up altitude over 5,500 feet ONLYVIIf Connect and adjust manometer Check Gas Control Set Point At Least 6 Inches +- Check-out procedure overviewVIIIa Check-out procedure checklistVIIIb ! ! ! ! ! ! ! ! Check-out procedure checklist (cont.)VIIIb Installation and service certificate Operation overviewIXa Operation sequenceIXb Steps Operation wiring diagramsIXb Figure 23 Ladder wiring diagram Notes Ladder diagram legend GCM Figure 24 Schematic wiring diagram Operation lighting instructionsIXc FOR YOUR SAFETY READ BEFORE OPERATING TO TURN OFF GAS TO THE APPLIANCE OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING OPERATING INSTRUCTIONS TO TURN OFF GAS TO THE APPLIANCE Service and maintenance overviewXa Overview of this section Service and maintenance scheduleXb Service technician Table 4 Service and maintenance schedules A Owner maintenance Service & maintenance annual start-upXc Annual start-up only by qualified service technician inspect Reported problems Boiler area service start-up Start-up procedure Blower motor Oiled-bearing circulators Service & maint. annual start-up (cont.)Xc Air vents and air elimination Limit controls and cutoffs Expansion tank Gauges Igniter Service & maint. annual start-up (cont.)Xc Review with owner owner review Service & maint. special proceduresXd Condensate drain line check valve kit Service & maint. special proced. (cont.)Xd Cleaning boiler heating surfaces To clean heating surfaces To remove the blower assembly Replace blower assembly Page Troubleshooting overviewXIa Troubleshooting proceduresXIb Troubleshooting air pressure switchXIc Checking the air pressure switch Check switch pressure setting Troubleshooting air pressure reading Return to normal operation Troubleshooting servicing tipsXId Igniter Blower Housing Robertshaw Model 7200DERN-680 White-Rodgers Model 36E66-302 Gas Valve Troubleshooting control moduleXIe Control Module Non-lockout light conditions TSTAT CIRC light flashing alone LIMIT light flashing alone Figure 34 GCM (control module) harness plug receptacle and indicator light locations. Indicator lights POWER TSTAT CIRC LIMIT PRES SWITCH FLAME Red Black Troubleshooting common problemsXIf Symptom Common Causes Possible Corrections Rapid cycling boiler turns on and off frequently Black water condition Frequent release of water through relief val ve Symptom Common Causes Possible Corrections Popping 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 Troubleshooting GCM lightsXIg POWER light off? POWER Is CHART 2 POWER Is boiler internal Bypass circulator operating? Figure 34, Item 4 & CHART 3 POWER Does the ohmmeter indicate a shorted sensor (zero ohms)? Figure 34, Item 6 Is boiler hot? CHART 4 PRES SWITCH & POWER Is purge light flashing? Does the voltmeter indicate Figure 34, Item 3 CHART 5 FLAME & POWER across gas valve terminals? 24 VAC lights flashing? CHART 6 POWER Are both boiler internal circulators operating? light flashing and TSTAT CIRC CHART 7 POWER light flashing and LIMIT CHART 8 POWER Are block switch contacts closed? Are limit switch contacts closed? Is Replacement parts overviewXIIa Replacement parts accessory bagXIIb Table 5 The parts below are shipped with the boiler in the accessory bag. Item number Description Model Weil-McLain part number Replacement parts section assemblyXIIc Page Replacement parts jacket assemblyXIId Item number Description Model Weil-McLain part number Page Replacement parts Blower assemblyXIIe Table 8 Blower assembly propane to natural natural to propane Item number Page Replacement parts trim assemblyXIIf Item number Description Weil-McLain part number Page Replacement parts interior panelXIIg Page Dimensions and ratingsXIII Figure 40 Dimension drawing (see dimension table on opposite page) L L