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

• Installation • Start-Up • Parts • Maintenance

Contents

	Contents		Summary	Pages
	Contents		Summary	Pages

	VII. Start-up		• Determine water treatment needs, if any.	42 – 47
			Obtain correct antifreeze if freeze protection required.
			Check for gas leaks (have propane odorant verified by supplier).
			Fill system and purge air.
			Read Operating instructions, section IX, then start boiler.
			Check all piping and verify leak-free.
			Check gas valve outlet pressure (altitudes over 5,500 feet).

	VIII.Check-out procedure		Complete checklist and fill out certificate.	48 – 49

	IX.	Operation	GCM (control module) indicator lights and sequence of opera-	50 – 55
			tion.
			Ladder wiring diagram (page 52).
			Schematic wiring diagram (page 53).
			Lighting instruction sheet — boiler with Robertshaw 7200DERN
			gas valve (page 54).
			Lighting instruction sheet — boiler with White-Rodgers 36E gas
			valve (page 55).

	X.	Service and maintenance	Service/maintenance schedule table (page 57).	56 – 65
			Detailed instructions for annual start-up and service.
			Special procedures for condensate drain line check valve (page
			63, if needed) and cleaning boiler heating surfaces (page 64).

	XI.	Troubleshooting	Troubleshooting procedures (page 67).	66 – 81
			Checking air pressure switch (page 68).
			Servicing tips and precautions — Igniter, gas valve and blower
			housing (page 69).
			Servicing tips and precautions plus indicator lights and lockout
			modes of GCM (control module) (page 70).
			Common problems and solutions (pages 72 and 73).
			Troubleshooting based on GCM indicator lights (pages 74 – 81).

	XII. Replacement parts		Accessory bag assembly shipped with boiler (page 83).	82 – 93
			Section assembly parts (page 84).
			Jacket assembly parts (page 86).
			Blower assembly parts (page 88).
			Trim assembly parts (page 90).
			Interior panel parts (page 92).

	XIII.Dimensions and ratings		Dimensional drawing and boiler rating table.	94 – 95

	Part number 550-141-850/0699			7

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

Contents

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