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Weil-McLain 550-141-850/0599, GOLD DV WATER BOILER manual GOLD GV Water boiler — Series

Models: GOLD DV WATER BOILER 550-141-850/0599

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Ž Installation • Start-Up • Parts • Maintenance

GOLD GV Water boiler — Series 3

a	supply to system	f	pressure/temperature gauge
b	return from system	g	flueway inspection port cover
c	combustion air inlet fitting	h	sensor hose trap
d	flue outlet	i	manual air vent
e	gas valve (see warning, right)	j	relief valve	85001

Part number 550-141-850/0699

This boiler uses a negative-pressure-

regulated gas valve, set for an outlet pressure approximately –0.20"w.c.. DO NOT set the outlet pressure higher than factory setting.

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Weil-McLain 550-141-850/0599 manual GOLD GV Water boiler — Series, Ž Installation • Start-Up• Parts • Maintenance

Contents

Boiler manual • Installation• Maintenance GOLD GV⑧Water temperature sensor How it works④Air pressure switch ⑤Water temperature limit switchŽ Installation • Start-Up• Parts • Maintenance GOLD GV Water boiler — SeriesHazard definitions Installer User Please read before proceedingGOLD GV Water boiler series 3 — manual Boiler operation — • Installation • Start-Up• Parts • MaintenanceWhen servicing boiler Please read before proceedingSummary ContentsContents GOLD GV Water boiler series 3 — manualSummary Contents• Installation • Start-Up• Parts • Maintenance ContentsIa Prepare boiler location — overview Overview of this sectionGOLD GV Water boiler series 3 — manual Installation Start-Up Parts Maintenance High altitude installationsInstallations must follow these codes Ib Prepare boiler location - codes & altitudeLarge space Ic Prepare boiler location - clearancesClearance options GOLD GV Water boiler series 3 — manualPrecautions Residential garage installationFlooring and foundation Installation Start-Up Parts MaintenanceWhen removing a boiler Id Prepare boiler location — vent systemRemoving from existing vent GV special vent systemTable 2 Corrosive contaminants Ie Prepare boiler location — contaminationAir contamination •Installation • Start-Up• Parts • MaintenanceSingle air opening option If Prepare boiler location — air openingsGV combustion air options Sizing air openingsExhaust fans and air movers Special considerations•Installation • Start-Up• Parts • Maintenance GV in small space less than Fig. 1 — aloneGOLD GV Water boiler series 3 — manual IIa Prepare boiler — overviewIIb Prepare boiler — vent starter tee & drain Overview of this sectionBase rail • Installation • Start-Up• Parts • Maintenanceplacing boiler Screw holeNatural gas IIc Prepare boiler — orifice platePlate installation GOLD GV Water boiler series 3 — manualWhite side propane plate •Installation • Start-Up• Parts • Maintenanceinstallation.85004b Bottom side of boiler front sectionCheck gas valve outlet pressure Install high altitude air pressure switchIId Prepare boiler — high altitude kit Obtain high altitude kitJacket left side panel altitudes above 5,500 feet ONLY• Installation • Start-Up• Parts • Maintenance White hose Red hoseIIe Prepare boiler — place in position GOLD GV Water boiler series 3 — manualPart number 550-141-850/0699 Clip shipping ROTATE• Installation • Start-Up• Parts • Maintenance ROTATEPrepare boiler for test Fig. IIf Prepare boiler — pressure testPerform hydrostatic pressure test GOLD GV Water boiler series 3 — manualTo fill/drain • Installation • Start-Up• Parts • MaintenanceFigure 7 Piping connections for hydrostatic test Part number 550-141-850/0699IIIa Water piping — overview Overview of this sectionGOLD GV Water boiler series 3 — manual Install and pipe relief valve Install relief valveIIIb Water piping — relief valve •Installation • Start-Up• Parts • MaintenanceExpansion tank IIIc Water piping — boiler connectionsSupply & return connections Air separatortype expansion • Installation • Start-Up• Parts • MaintenanceFigure Figure 10 Piping closedZoning with zone valves IIId Water piping — all systemsAdditional components Zoning with circulatorsBoiler pressure/temperature gauge IIIe Water piping — baseboard systemBaseboard system piping Installation Start-Up Parts MaintenanceLegend IIIf Water piping — radiator systemRadiator system piping GOLD GV Water boiler series 3 — manualLegend • Installation • Start-Up• Parts • MaintenanceAlumiPex Controls • Pumps • Wiring Design Guide Adjust balancing valvesSystem supply temperature gauge Outdoor reset controlIIIh Water piping — multi-zoneradiant system Multi-zoneradiant heating system pipingPart number 550-141-850/0699 IIIi Water piping — snow melt system•Installation • Start-Up• Parts • Maintenance LegendIIIj Water piping - water chiller systems Water chiller systemsGOLD GV Water boiler series 3 - manual •combustion air quality IV Venting and combustion air• Installation • Start-Up• Parts • Maintenance •vent system •combustion air openingsNatural Gas Connecting gas supply piping to boilerV Gas piping GOLD GV Water boiler series 3 — manual• Installation • Start-Up• Parts • Maintenance feetCapacity of pipe for pipe size of GOLD GV Water boiler series 3 — manual VI Field wiringElectrical installation must comply with Wiring connectionsPart number 550-141-850/0699 •Installation • Start-Up• Parts • MaintenanceVerify water chemistry Freeze protection when usedVIIa Start-up— overview VIIb Start-up— preparationFill the system with water VIIb Start-up— preparation contVerify 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 boilerPart number 550-141-850/0699 VIId Start-up— operate boiler contVIIe Start-up— if boiler doesn’t start •Installation • Start-Up• Parts • MaintenanceCheck Gas Control Set Point VIIf Start-up— altitude over 5,500 feet ONLYConnect and adjust manometer GOLD GV Water boiler series 3 — manualAt Least 6 Inches •Installation • Start-Up• Parts • MaintenanceVIIIb VIIIa Check-outprocedure — overviewCheck-outprocedure — checklist Check off steps as completedInstallation Start-Up Parts Maintenance VIIIb Check-outprocedure — checklist contPart number 550-141-850/0699 IXa Operation — overviewOverview of this section GOLD GV Water boiler series 3 — manualStandby IXb Operation — sequenceSteps • Installation • Start-Up• Parts • Maintenance120 VAC hot field wiring IXb Operation — wiring diagramsFigure 23 Ladder wiring diagram Ladder diagram legendGround connectors •Installation • Start-Up• Parts • MaintenanceFigure 24 Schematic wiring diagram Plug-inconnectorsTO TURN OFF GAS TO THE APPLIANCE FOR YOUR SAFETY READ BEFORE OPERATINGIXc Operation — lighting instructions OPERATING INSTRUCTIONSTO TURN OFF GAS TO THE APPLIANCE FOR YOUR SAFETY READ BEFORE OPERATING• Installation • Start-Up• Parts • Maintenance OPERATING INSTRUCTIONSXa Service and maintenance - overview GOLD GV Water boiler series 3 — manualPart number 550-141-850/0699 Service Xb Service and maintenance — scheduleInstallation Start-Up Parts Maintenance Service technicianGOLD GV Water boiler series 3 — manual Xc Service & maintenance — annual start-upAnnual start-up— inspect Reported problems•Installation • Start-Up• Parts • Maintenance Annual start-up— servicestart-up Annual start-upGOLD GV Water boiler series 3 — manual Xc Service & maint. — annual start-up contAnnual start-up— check/test Temperature mixing systemGauges •Installation • Start-Up• Parts • MaintenanceAnnual start-up— check/test Expansion tankGOLD GV Water boiler series 3 — manual Annual start-up— owner reviewXc Service & maint. — annual start-up cont Annual start-up— check/testcheck valve assembly Xd Service & maint. — special proceduresCondensate drain line check valve kit Installation Start-Up Parts MaintenanceTo clean heating surfaces Xd Service & maint. — special proced. contCleaning boiler heating surfaces To remove the blower assemblyAir pressure switch Blower motor wiring harness IgniterGas/air orifice plate XIa Troubleshooting - overview Overview of this sectionGOLD GV Water boiler series 3 — manual VERIFY PROPER OPERATION AFTER SERVICING XIb Troubleshooting - proceduresBefore troubleshooting Check the followingTroubleshooting air pressure reading XIc Troubleshooting - air pressure switchChecking the air pressure switch Check switch pressure settingGas Valve XId Troubleshooting — servicing tipsBlower Housing IgniterTroubleshooting the GCM XIe Troubleshooting — control moduleControl Module Control indicator lights — lockout modesPRES SWITCH •Installation • Start-Up• Parts • MaintenancePOWER Indicator lightsPossible Corrections XIf Troubleshooting — common problemsSymptom Common Causes• Installation • Start-Up• Parts • Maintenance SymptomCommon Causes Possible CorrectionsChart XIg Troubleshooting — GCM lightsCHART 1 — Troubleshooting POWER light status Is POWER light off?Does the voltmeter indicate 120 VAC? • Installation • Start-Up• Parts • MaintenanceCHART 2 — TSTAT CIRC & POWER lights flashing Does problem persist?Is boiler hot? XIg Troubleshooting — GCM lights continuedCHART 3 — LIMIT & POWER lights flashing GOLD GV Water boiler series 3 — manualDoes the ohmmeter indicate the switch is closed? • Installation • Start-Up• Parts • MaintenanceCHART 4 — PRES SWITCH & POWER lights flashing TURN OFF POWER at service switchAre FLAME & POWER lights flashing? XIg Troubleshooting — GCM lights continuedCHART 5 — FLAME & POWER lights flashing Are FLAME & POWER lights flashing?temperature sensor • Installation • Start-Up• Parts • MaintenanceIs return water temperature sensor clamped If problem persistsDoes LIMIT light still flash? XIg Troubleshooting — GCM lights continuedGOLD GV Water boiler series 3 — manual Part number 550-141-850/0699Is boiler System circulator operating? •Installation • Start-Up• Parts • MaintenanceDoes voltmeter show 120 VAC across pins? Are block switch contacts closed?GOLD GV Water boiler series 3 — manual XIIa Replacement parts - overviewPart number 550-141-850/0699 XIIb Replacement parts — accessory bagInstallation Start-Up Parts Maintenance TableDescription XIIc Replacement parts — section assemblyGOLD GV Water boiler series 3 - manual Item• Installation • Start-Up• Parts • Maintenance Figure 35 Section assemblyPart number 550-141-850/0699 Description XIId Replacement parts - jacket assemblyGOLD GV Water boiler series 3 — manual Item• Installation • Start-Up• Parts • Maintenance Figure 36 Jacket assemblyPart number 550-141-850/0699 Item XIIe Replacement parts — Blower assemblyTable 8 Blower assembly GOLD GV Water boiler series 3 — manualVent starter tee — not included Installation Start-Up Parts MaintenanceFigure 37 Blower assembly Part number 550-141-850/0699Item XIIf Replacement parts — trim assemblyTable 9 Trim assembly GOLD GV Water boiler series 3 - manual85048 • Installation • Start-Up• Parts • MaintenanceFigure 38 Trim assembly Part number 550-141-850/0699Description XIIg Replacement parts — interior panelGOLD GV Water boiler series 3 — manual ItemPart number 550-141-850/0699 • Installation • Start-Up• Parts • MaintenanceFigure Interior panelGOLD GV Water boiler series 3 — manual XIII Dimensions and ratingsweight • Installation • Start-Up• Parts • MaintenanceTable 11 Boiler dimensional data see Figure Crate dimensionsWeil-McLain 500 Blaine Street Michigan City, IN GOLD GV Water boiler - Series