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Weil-McLain 550-141-850/0599 • Installation • Start-Up• Parts • Maintenance, Section assembly

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

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• Installation • Start-Up • Parts • Maintenance

Figure 35 Section assembly

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Part number 550-141-850/0699

Page 85

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Weil-McLain 550-141-850/0599, GOLD DV WATER BOILER manual • Installation • Start-Up• Parts • Maintenance, Section assembly

Contents

• Maintenance • InstallationGOLD GV Boiler manual④Air pressure switch How it works⑤Water temperature limit switch ⑧Water temperature sensorŽ Installation • Start-Up• Parts • Maintenance GOLD GV Water boiler — SeriesPlease read before proceeding Hazard definitions Installer UserGOLD GV Water boiler series 3 — manual When servicing boiler • Installation • Start-Up• Parts • MaintenancePlease read before proceeding Boiler operation —Contents ContentsGOLD GV Water boiler series 3 — manual Summary• Installation • Start-Up• Parts • Maintenance ContentsContents SummaryOverview of this section Ia Prepare boiler location — overviewGOLD GV Water boiler series 3 — manual Installations must follow these codes High altitude installationsIb Prepare boiler location - codes & altitude Installation Start-Up Parts MaintenanceClearance options Ic Prepare boiler location - clearancesGOLD GV Water boiler series 3 — manual Large spaceFlooring and foundation Residential garage installationInstallation Start-Up Parts Maintenance PrecautionsRemoving from existing vent Id Prepare boiler location — vent systemGV special vent system When removing a boilerAir contamination Ie Prepare boiler location — contamination•Installation • Start-Up• Parts • Maintenance Table 2 Corrosive contaminantsGV combustion air options If Prepare boiler location — air openingsSizing air openings Single air opening option•Installation • Start-Up• Parts • Maintenance Special considerationsGV in small space less than Fig. 1 — alone Exhaust fans and air moversIIb Prepare boiler — vent starter tee & drain IIa Prepare boiler — overviewOverview of this section GOLD GV Water boiler series 3 — manualplacing boiler • Installation • Start-Up• Parts • MaintenanceScrew hole Base railPlate installation IIc Prepare boiler — orifice plateGOLD GV Water boiler series 3 — manual Natural gasinstallation.85004b •Installation • Start-Up• Parts • MaintenanceBottom side of boiler front section White side propane plateIId Prepare boiler — high altitude kit Install high altitude air pressure switchObtain high altitude kit Check gas valve outlet pressure• Installation • Start-Up• Parts • Maintenance altitudes above 5,500 feet ONLYWhite hose Red hose Jacket left side panelGOLD GV Water boiler series 3 — manual IIe Prepare boiler — place in positionPart number 550-141-850/0699 • Installation • Start-Up• Parts • Maintenance ROTATEROTATE Clip shippingPerform hydrostatic pressure test IIf Prepare boiler — pressure testGOLD GV Water boiler series 3 — manual Prepare boiler for test Fig.Figure 7 Piping connections for hydrostatic test • Installation • Start-Up• Parts • MaintenancePart number 550-141-850/0699 To fill/drainOverview of this section IIIa Water piping — overviewGOLD GV Water boiler series 3 — manual IIIb Water piping — relief valve Install relief valve•Installation • Start-Up• Parts • Maintenance Install and pipe relief valveSupply & return connections IIIc Water piping — boiler connectionsAir separator Expansion tankFigure • Installation • Start-Up• Parts • MaintenanceFigure 10 Piping closed type expansionAdditional components IIId Water piping — all systemsZoning with circulators Zoning with zone valvesBaseboard system piping IIIe Water piping — baseboard systemInstallation Start-Up Parts Maintenance Boiler pressure/temperature gaugeRadiator system piping IIIf Water piping — radiator systemGOLD GV Water boiler series 3 — manual LegendAlumiPex Controls • Pumps • Wiring Design Guide • Installation • Start-Up• Parts • MaintenanceAdjust balancing valves LegendIIIh Water piping — multi-zoneradiant system Outdoor reset controlMulti-zoneradiant heating system piping System supply temperature gauge•Installation • Start-Up• Parts • Maintenance IIIi Water piping — snow melt systemLegend Part number 550-141-850/0699Water chiller systems IIIj Water piping - water chiller systemsGOLD GV Water boiler series 3 - manual • Installation • Start-Up• Parts • Maintenance IV Venting and combustion air•vent system •combustion air openings •combustion air qualityV Gas piping Connecting gas supply piping to boilerGOLD GV Water boiler series 3 — manual Natural Gasfeet • Installation • Start-Up• Parts • MaintenanceCapacity of pipe for pipe size of Electrical installation must comply with VI Field wiringWiring connections GOLD GV Water boiler series 3 — manualPart number 550-141-850/0699 •Installation • Start-Up• Parts • MaintenanceVIIa Start-up— overview Freeze protection when usedVIIb Start-up— preparation Verify water chemistryVerify gas/air orifice plate VIIb Start-up— preparation contCheck for gas leaks Fill the system with waterVIId Start-up— to operate boiler VIIc Start-up— read SectionPerform final checks before starting boiler Start the boilerVIIe Start-up— if boiler doesn’t start VIId Start-up— operate boiler cont•Installation • Start-Up• Parts • Maintenance Part number 550-141-850/0699Connect and adjust manometer VIIf Start-up— altitude over 5,500 feet ONLYGOLD GV Water boiler series 3 — manual Check Gas Control Set PointAt Least 6 Inches •Installation • Start-Up• Parts • MaintenanceCheck-outprocedure — checklist VIIIa Check-outprocedure — overviewCheck off steps as completed VIIIbInstallation Start-Up Parts Maintenance VIIIb Check-outprocedure — checklist contOverview of this section IXa Operation — overviewGOLD GV Water boiler series 3 — manual Part number 550-141-850/0699Steps IXb Operation — sequence• Installation • Start-Up• Parts • Maintenance StandbyFigure 23 Ladder wiring diagram IXb Operation — wiring diagramsLadder diagram legend 120 VAC hot field wiringFigure 24 Schematic wiring diagram •Installation • Start-Up• Parts • MaintenancePlug-inconnectors Ground connectorsIXc Operation — lighting instructions FOR YOUR SAFETY READ BEFORE OPERATINGOPERATING INSTRUCTIONS TO TURN OFF GAS TO THE APPLIANCE• Installation • Start-Up• Parts • Maintenance FOR YOUR SAFETY READ BEFORE OPERATINGOPERATING INSTRUCTIONS TO TURN OFF GAS TO THE APPLIANCEGOLD GV Water boiler series 3 — manual Xa Service and maintenance - overviewPart number 550-141-850/0699 Installation Start-Up Parts Maintenance Xb Service and maintenance — scheduleService technician ServiceAnnual start-up— inspect Xc Service & maintenance — annual start-upReported problems GOLD GV Water boiler series 3 — manualstart-up Annual start-up— serviceAnnual start-up •Installation • Start-Up• Parts • MaintenanceAnnual start-up— check/test Xc Service & maint. — annual start-up contTemperature mixing system GOLD GV Water boiler series 3 — manualAnnual start-up— check/test •Installation • Start-Up• Parts • MaintenanceExpansion tank GaugesXc Service & maint. — annual start-up cont Annual start-up— owner reviewAnnual start-up— check/test GOLD GV Water boiler series 3 — manualCondensate drain line check valve kit Xd Service & maint. — special proceduresInstallation Start-Up Parts Maintenance check valve assemblyCleaning boiler heating surfaces Xd Service & maint. — special proced. contTo remove the blower assembly To clean heating surfacesIgniter Air pressure switch Blower motor wiring harnessGas/air orifice plate Overview of this section XIa Troubleshooting - overviewGOLD GV Water boiler series 3 — manual Before troubleshooting XIb Troubleshooting - proceduresCheck the following VERIFY PROPER OPERATION AFTER SERVICINGChecking the air pressure switch XIc Troubleshooting - air pressure switchCheck switch pressure setting Troubleshooting air pressure readingBlower Housing XId Troubleshooting — servicing tipsIgniter Gas ValveControl Module XIe Troubleshooting — control moduleControl indicator lights — lockout modes Troubleshooting the GCMPOWER •Installation • Start-Up• Parts • MaintenanceIndicator lights PRES SWITCHSymptom XIf Troubleshooting — common problemsCommon Causes Possible CorrectionsCommon Causes SymptomPossible Corrections • Installation • Start-Up• Parts • MaintenanceCHART 1 — Troubleshooting POWER light status XIg Troubleshooting — GCM lightsIs POWER light off? ChartCHART 2 — TSTAT CIRC & POWER lights flashing • Installation • Start-Up• Parts • MaintenanceDoes problem persist? Does the voltmeter indicate 120 VAC?CHART 3 — LIMIT & POWER lights flashing XIg Troubleshooting — GCM lights continuedGOLD GV Water boiler series 3 — manual Is boiler hot?CHART 4 — PRES SWITCH & POWER lights flashing • Installation • Start-Up• Parts • MaintenanceTURN OFF POWER at service switch Does the ohmmeter indicate the switch is closed?CHART 5 — FLAME & POWER lights flashing XIg Troubleshooting — GCM lights continuedAre FLAME & POWER lights flashing? Are FLAME & POWER lights flashing?Is return water temperature sensor clamped • Installation • Start-Up• Parts • MaintenanceIf problem persists temperature sensorGOLD GV Water boiler series 3 — manual XIg Troubleshooting — GCM lights continuedPart number 550-141-850/0699 Does LIMIT light still flash?Does voltmeter show 120 VAC across pins? •Installation • Start-Up• Parts • MaintenanceAre block switch contacts closed? Is boiler System circulator operating?GOLD GV Water boiler series 3 — manual XIIa Replacement parts - overviewInstallation Start-Up Parts Maintenance XIIb Replacement parts — accessory bagTable Part number 550-141-850/0699GOLD GV Water boiler series 3 - manual XIIc Replacement parts — section assemblyItem DescriptionFigure 35 Section assembly • Installation • Start-Up• Parts • MaintenancePart number 550-141-850/0699 GOLD GV Water boiler series 3 — manual XIId Replacement parts - jacket assemblyItem DescriptionFigure 36 Jacket assembly • Installation • Start-Up• Parts • MaintenancePart number 550-141-850/0699 Table 8 Blower assembly XIIe Replacement parts — Blower assemblyGOLD GV Water boiler series 3 — manual ItemFigure 37 Blower assembly Installation Start-Up Parts MaintenancePart number 550-141-850/0699 Vent starter tee — not includedTable 9 Trim assembly XIIf Replacement parts — trim assemblyGOLD GV Water boiler series 3 - manual ItemFigure 38 Trim assembly • Installation • Start-Up• Parts • MaintenancePart number 550-141-850/0699 85048GOLD GV Water boiler series 3 — manual XIIg Replacement parts — interior panelItem DescriptionFigure • Installation • Start-Up• Parts • MaintenanceInterior panel Part number 550-141-850/0699GOLD GV Water boiler series 3 — manual XIII Dimensions and ratingsTable 11 Boiler dimensional data see Figure • Installation • Start-Up• Parts • MaintenanceCrate dimensions weightWeil-McLain 500 Blaine Street Michigan City, IN GOLD GV Water boiler - Series