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Weil-McLain 550-141-850/0599, GOLD DV WATER BOILER IIIi Water piping — snow melt system, Legend

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

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IIIi Water piping — snow melt system

•Installation • Start-Up • Parts • Maintenance

IIIi Water piping — snow melt system

Figure 15a Manual bypass valves; for fixed temp operation only

Snow melt

heat exchanger

Heating zone(s)

12"

max

Cold water

fill

GV Boiler

85014b

Figure 15b Auto return temp regulation; for outdoor reset or fixed temp

Snow melt

heat exchanger

Heating zone(s)

12"

max

Cold water

fill

GV Boiler

85016

Piping snow melt systems or combination snow melt/ space heating systems

Combination snow melt/space heating systems will have widely varying system return temperatures. So these systems require automatic return water temperature as shown in Figure 15a (zone-valve zoning) or Figure 15b (circulator zoning).

Select an automatic temperature control valve or motor- operated valve which can be adjusted to provide a return water temperature of at least 60 °F. Any setting higher than 60 °F will also be acceptable.

Zone-valve zoning — The suggested piping uses a separate circulator for system circulation to assure good temperature distribution in the system when the return water temperature is low.

Circulator zoning — The GV internal circulators must not be removed. Provide a separate circulator for each zone.

The return water temperature to the boiler must be at least 60 °F. Provide and apply means to regulate the return temperature. Failure to do so can result in boiler control operation problems, causing possible significant property damage.

Legend

1Boiler isolation valves

2Automatic air vent (with diaphragm-type expansion tank), or connect to tank fitting (closed-type expansion tank).

3Diaphragm- or bladder-type expansion tank, if used (For closed-type expansion tank, pipe from top of air separator to tank fitting as in Figure 10.)

4Zone valve

5System or zone circulator

6Flow/check valve

7Hose bibb purge valve

8Boiler pressure/temperature gauge

9System supply temperature gauge

12Return temperature automatic mixing valve

Part number 550-141-850/0699

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Image 35

Weil-McLain 550-141-850/0599 IIIi Water piping — snow melt system, •Installation • Start-Up• Parts • Maintenance, Legend

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 — SeriesGOLD GV Water boiler series 3 — manual Hazard definitions Installer UserPlease read before proceeding 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 ContentsGOLD GV Water boiler series 3 — manual Ia Prepare boiler location — overviewOverview of this section 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 hosePart number 550-141-850/0699 IIe Prepare boiler — place in positionGOLD GV Water boiler series 3 — manual 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 550-141-850/0699GOLD GV Water boiler series 3 — manual IIIa Water piping — overviewOverview of this section 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 LegendGOLD GV Water boiler series 3 - manual IIIj Water piping - water chiller systemsWater chiller systems •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 — manualCapacity of pipe for pipe size of • Installation • Start-Up• Parts • Maintenancefeet 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 INSTRUCTIONSPart number 550-141-850/0699 Xa Service and maintenance - overviewGOLD GV Water boiler series 3 — manual 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 assemblyGas/air orifice plate Air pressure switch Blower motor wiring harnessIgniter GOLD GV Water boiler series 3 — manual XIa Troubleshooting - overviewOverview of this section 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 ItemPart number 550-141-850/0699 • Installation • Start-Up• Parts • MaintenanceFigure 35 Section assembly Description XIId Replacement parts - jacket assemblyGOLD GV Water boiler series 3 — manual ItemPart number 550-141-850/0699 • Installation • Start-Up• Parts • MaintenanceFigure 36 Jacket assembly 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