Check-out procedure checklist | Weil-McLain GOLD DV WATER BOILER

GOLD GV Water boiler series 3 — manual

VIIIa Check-out procedure — overview

Overview of this section

❏Perform the checklist following to ensure boiler is operating correctly.

❏Fill in the Installation and service certificate at the end of the checklist.

VIIIb

Check off steps as completed

Check-out procedure — checklist

!Boiler and heat distribution units filled with water?

!Automatic air vent, if used, open one full turn?

!Air purged from system?

!Air purged from gas piping? Piping checked for leaks?

!Is proper orifice plate installed? Refer to manual Section IIc to check size and fuel type.

Proper orifice plate must be used. Failure to do so will cause severe personal injury, death or substantial property damage.

!Followed operating instructions on boiler or in manual Section VII for proper start-up?

!Is igniter glow visible? Refer to Verify igniter operation, manual Section VIId, step 5.

!Inspect vent system for leaks. Verify vent (and air) piping are functional and unobstructed.

!Test limit control — While burner is operating, move indicator on limit control below actual boiler water temperature. Blower and burner should go off while circulator continues to operate. Raise setting on limit control above boiler water temperature and burner should reignite.

!Test additional field-installed controls — If boiler has a low water cutoff, additional high limit or other controls, test for operation as outlined by manufacturer. Burner should be operating and should go off when controls are tested. When controls are restored, boiler should restart.

!Test ignition system (control module):

a.Connect voltmeter to gas valve terminals.

b.Turn off manual gas valve.

c.Set thermostat to call for heat.

d.Control module will begin purge cycle, then activate igniter. Igniter will glow for approximately 20 seconds. Near end of 20 seconds, 24 VAC will show at gas valve for approximately 6 seconds and then

48	Part number 550-141-850/0699

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Weil-McLain GOLD DV WATER BOILER, 550-141-850/0599 manual VIIIa Check-out procedure overview, Check-out procedure checklist

Contents

Gold GV How it works Gold GV Water boiler Series Hazard definitions Installer User Please read before proceeding When servicing boiler Boiler operationBoiler water Contents Contents Ia Prepare boiler location overview Overview of this section Installations must follow these codes Ib Prepare boiler location codes & altitude Ic Prepare boiler location clearances Clearance optionsLarge space Small space Residential garage installation PrecautionsFlooring and foundation Flooring Id Prepare boiler location vent system Removing from existing ventGV special vent system Ie Prepare boiler location contamination Air contamination If Prepare boiler location air openings Special considerations GV in small space less than alone IIa Prepare boiler overview IIb Prepare boiler vent starter tee & drain Screw hole Base rail Insert Cpvc elbow Plate installation IIc Prepare boiler orifice plateNatural gas Propane Bottom side of boiler front section When required IId Prepare boiler high altitude kit Altitudes above 5,500 feet only White Hose Red IIe Prepare boiler place in position Rotate IIf Prepare boiler pressure test Perform hydrostatic pressure testPrepare boiler for test Fig Fill and pressure test Piping connections for hydrostatic test IIIa Water piping overview For heating system with See pages 27 30 Install relief valve IIIb Water piping relief valve IIIc Water piping boiler connections Supply & return connectionsAir separator Expansion tank Piping closed IIId Water piping all systems Zoning with circulators IIIe Water piping baseboard system Baseboard system piping IIIf Water piping radiator system Radiator system piping IIIg Water piping single-zone radiant or heat pump system Outdoor reset control IIIh Water piping multi-zone radiant systemMulti-zone radiant heating system piping IIIi Water piping snow melt system Manual bypass valves for fixed temp operation only IIIj Water piping water chiller systems Water chiller systems IV Venting and combustion air Connecting gas supply piping to boiler Gas pipingPropane Gas Feet VI Field wiring Electrical installation must comply withWiring connections Thermostats Field wiring Factory wiring Freeze protection when used VIIa Start-up overviewVIIb Start-up preparation Verify water chemistry VIIb Start-up preparation Verify gas/air orifice plateCheck for gas leaks Fill the system with water VIIc Start-up read Section VIId Start-up to operate boilerPerform final checks before starting boiler Start the boiler VIId Start-up operate boiler VIIe Start-up if boiler doesn’t start Connect and adjust manometer VIIf Start-up altitude over 5,500 feet onlyCheck Gas Control Set Point At Least Inches VIIIa Check-out procedure overview Check-out procedure checklist VIIIb Check-out procedure checklist Shows the ladder wiring diagram for the GV series 3 boiler IXa Operation overview IXb Operation sequence Steps IXb Operation wiring diagrams Ladder diagram legend GCM For Your Safety Read Before Operating IXc Operation lighting instructions White-Rodgers gas valve model 36E Xa Service and maintenance overview Xb Service and maintenance schedule Service technician Xc Service & maintenance annual start-up Annual start-up only by qualified service technician Start-up Xc Service & maint. annual start-upcont Annual start-up check/test Expansion 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 XIc Troubleshooting air pressure switch Checking the air pressure switch XId Troubleshooting servicing tips Blower HousingIgniter Gas Valve XIe Troubleshooting control module Control Module Power XIf Troubleshooting common problems Symptom Common Causes Possible Corrections Symptom Common Causes Possible Corrections XIg Troubleshooting GCM lights Chart 1 Troubleshooting Power light status Chart 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 XIIb Replacement parts accessory bag Water trim bag assembly #1 XIIc Replacement parts section assembly Description Model Weil-McLain Number Part number 85041 XIId Replacement parts jacket assembly 422-200-228 85042 XIIe Replacement parts Blower assembly 382-200-340 Vent starter tee not included XIIf Replacement parts trim assembly Description Weil-McLain Number Part number 85048 XIIg Replacement parts interior panel Interior panel Xiii Dimensions and ratings Number DOE Gold GV Water boiler Series