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

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

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Page 96

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GOLD GV Water boiler — Series 3

Weil-McLain

500 Blaine Street

Michigan City, IN 46360-2388

http://www.weil-mclain.com

96	Part number 550-141-850/0699

Page 96

Image 96

Weil-McLain GOLD DV WATER BOILER manual GOLD GV Water boiler - Series, Weil-McLain 500 Blaine Street Michigan City, IN

Contents

• Installation • MaintenanceGOLD GV Boiler manualHow it works ④Air pressure switch⑤Water temperature limit switch ⑧Water temperature sensorGOLD GV Water boiler — Series Ž Installation • Start-Up• Parts • MaintenanceHazard definitions Installer User Please read before proceedingGOLD GV Water boiler series 3 — manual • Installation • Start-Up• Parts • Maintenance When servicing boilerPlease read before proceeding Boiler operation —Contents ContentsGOLD GV Water boiler series 3 — manual SummaryContents • Installation • Start-Up• Parts • MaintenanceContents SummaryIa Prepare boiler location — overview Overview of this sectionGOLD GV Water boiler series 3 — manual High altitude installations Installations must follow these codesIb Prepare boiler location - codes & altitude Installation Start-Up Parts MaintenanceIc Prepare boiler location - clearances Clearance optionsGOLD GV Water boiler series 3 — manual Large spaceResidential garage installation Flooring and foundationInstallation Start-Up Parts Maintenance PrecautionsId Prepare boiler location — vent system Removing from existing ventGV special vent system When removing a boilerIe Prepare boiler location — contamination Air contamination•Installation • Start-Up• Parts • Maintenance Table 2 Corrosive contaminantsIf Prepare boiler location — air openings GV combustion air optionsSizing air openings Single air opening optionSpecial considerations •Installation • Start-Up• Parts • MaintenanceGV in small space less than Fig. 1 — alone Exhaust fans and air moversIIa Prepare boiler — overview IIb Prepare boiler — vent starter tee & drainOverview of this section GOLD GV Water boiler series 3 — manual• Installation • Start-Up• Parts • Maintenance placing boilerScrew hole Base railIIc Prepare boiler — orifice plate Plate installationGOLD GV Water boiler series 3 — manual Natural gas•Installation • Start-Up• Parts • Maintenance installation.85004bBottom side of boiler front section White side propane plateInstall high altitude air pressure switch IId Prepare boiler — high altitude kitObtain high altitude kit Check gas valve outlet pressurealtitudes above 5,500 feet ONLY • Installation • Start-Up• Parts • MaintenanceWhite hose Red hose Jacket left side panelIIe Prepare boiler — place in position GOLD GV Water boiler series 3 — manualPart number 550-141-850/0699 ROTATE • Installation • Start-Up• Parts • MaintenanceROTATE Clip shippingIIf Prepare boiler — pressure test Perform hydrostatic pressure testGOLD GV Water boiler series 3 — manual Prepare boiler for test Fig.• Installation • Start-Up• Parts • Maintenance Figure 7 Piping connections for hydrostatic testPart number 550-141-850/0699 To fill/drainIIIa Water piping — overview Overview of this sectionGOLD GV Water boiler series 3 — manual Install relief valve IIIb Water piping — relief valve•Installation • Start-Up• Parts • Maintenance Install and pipe relief valveIIIc Water piping — boiler connections Supply & return connectionsAir separator Expansion tank• Installation • Start-Up• Parts • Maintenance FigureFigure 10 Piping closed type expansionIIId Water piping — all systems Additional componentsZoning with circulators Zoning with zone valvesIIIe Water piping — baseboard system Baseboard system pipingInstallation Start-Up Parts Maintenance Boiler pressure/temperature gaugeIIIf Water piping — radiator system Radiator system pipingGOLD GV Water boiler series 3 — manual Legend• Installation • Start-Up• Parts • Maintenance AlumiPex Controls • Pumps • Wiring Design GuideAdjust balancing valves LegendOutdoor reset control IIIh Water piping — multi-zoneradiant systemMulti-zoneradiant heating system piping System supply temperature gaugeIIIi Water piping — snow melt system •Installation • Start-Up• Parts • MaintenanceLegend Part number 550-141-850/0699IIIj Water piping - water chiller systems Water chiller systemsGOLD GV Water boiler series 3 - manual IV Venting and combustion air • Installation • Start-Up• Parts • Maintenance•vent system •combustion air openings •combustion air qualityConnecting gas supply piping to boiler V Gas pipingGOLD GV Water boiler series 3 — manual Natural Gas• Installation • Start-Up• Parts • Maintenance feetCapacity of pipe for pipe size of VI Field wiring Electrical installation must comply withWiring connections GOLD GV Water boiler series 3 — manual•Installation • Start-Up• Parts • Maintenance Part number 550-141-850/0699Freeze protection when used VIIa Start-up— overviewVIIb Start-up— preparation Verify water chemistryVIIb Start-up— preparation cont Verify gas/air orifice plateCheck for gas leaks Fill the system with waterVIIc Start-up— read Section VIId Start-up— to operate boilerPerform final checks before starting boiler Start the boilerVIId Start-up— operate boiler cont VIIe Start-up— if boiler doesn’t start•Installation • Start-Up• Parts • Maintenance Part number 550-141-850/0699VIIf Start-up— altitude over 5,500 feet ONLY Connect and adjust manometerGOLD GV Water boiler series 3 — manual Check Gas Control Set Point•Installation • Start-Up• Parts • Maintenance At Least 6 InchesVIIIa Check-outprocedure — overview Check-outprocedure — checklistCheck off steps as completed VIIIbVIIIb Check-outprocedure — checklist cont Installation Start-Up Parts MaintenanceIXa Operation — overview Overview of this sectionGOLD GV Water boiler series 3 — manual Part number 550-141-850/0699IXb Operation — sequence Steps• Installation • Start-Up• Parts • Maintenance StandbyIXb Operation — wiring diagrams Figure 23 Ladder wiring diagramLadder diagram legend 120 VAC hot field wiring•Installation • Start-Up• Parts • Maintenance Figure 24 Schematic wiring diagramPlug-inconnectors Ground connectorsFOR YOUR SAFETY READ BEFORE OPERATING IXc Operation — lighting instructionsOPERATING INSTRUCTIONS TO TURN OFF GAS TO THE APPLIANCEFOR YOUR SAFETY READ BEFORE OPERATING • Installation • Start-Up• Parts • MaintenanceOPERATING INSTRUCTIONS TO TURN OFF GAS TO THE APPLIANCEXa Service and maintenance - overview GOLD GV Water boiler series 3 — manualPart number 550-141-850/0699 Xb Service and maintenance — schedule Installation Start-Up Parts MaintenanceService technician ServiceXc Service & maintenance — annual start-up Annual start-up— inspectReported problems GOLD GV Water boiler series 3 — manualAnnual start-up— service start-upAnnual start-up •Installation • Start-Up• Parts • MaintenanceXc Service & maint. — annual start-up cont Annual start-up— check/testTemperature mixing system GOLD GV Water boiler series 3 — manual•Installation • Start-Up• Parts • Maintenance Annual start-up— check/testExpansion tank GaugesAnnual start-up— owner review Xc Service & maint. — annual start-up contAnnual start-up— check/test GOLD GV Water boiler series 3 — manualXd Service & maint. — special procedures Condensate drain line check valve kitInstallation Start-Up Parts Maintenance check valve assemblyXd Service & maint. — special proced. cont Cleaning boiler heating surfacesTo remove the blower assembly To clean heating surfacesAir pressure switch Blower motor wiring harness IgniterGas/air orifice plate XIa Troubleshooting - overview Overview of this sectionGOLD GV Water boiler series 3 — manual XIb Troubleshooting - procedures Before troubleshootingCheck the following VERIFY PROPER OPERATION AFTER SERVICINGXIc Troubleshooting - air pressure switch Checking the air pressure switchCheck switch pressure setting Troubleshooting air pressure readingXId Troubleshooting — servicing tips Blower HousingIgniter Gas ValveXIe Troubleshooting — control module Control ModuleControl indicator lights — lockout modes Troubleshooting the GCM•Installation • Start-Up• Parts • Maintenance POWERIndicator lights PRES SWITCHXIf Troubleshooting — common problems SymptomCommon Causes Possible CorrectionsSymptom Common CausesPossible Corrections • Installation • Start-Up• Parts • MaintenanceXIg Troubleshooting — GCM lights CHART 1 — Troubleshooting POWER light statusIs POWER light off? Chart• Installation • Start-Up• Parts • Maintenance CHART 2 — TSTAT CIRC & POWER lights flashingDoes problem persist? Does the voltmeter indicate 120 VAC?XIg Troubleshooting — GCM lights continued CHART 3 — LIMIT & POWER lights flashingGOLD GV Water boiler series 3 — manual Is boiler hot?• Installation • Start-Up• Parts • Maintenance CHART 4 — PRES SWITCH & POWER lights flashingTURN OFF POWER at service switch Does the ohmmeter indicate the switch is closed?XIg Troubleshooting — GCM lights continued CHART 5 — FLAME & POWER lights flashingAre FLAME & POWER lights flashing? Are FLAME & POWER lights flashing?• Installation • Start-Up• Parts • Maintenance Is return water temperature sensor clampedIf problem persists temperature sensorXIg Troubleshooting — GCM lights continued GOLD GV Water boiler series 3 — manualPart number 550-141-850/0699 Does LIMIT light still flash?•Installation • Start-Up• Parts • Maintenance Does voltmeter show 120 VAC across pins?Are block switch contacts closed? Is boiler System circulator operating?XIIa Replacement parts - overview GOLD GV Water boiler series 3 — manualXIIb Replacement parts — accessory bag Installation Start-Up Parts MaintenanceTable Part number 550-141-850/0699XIIc Replacement parts — section assembly GOLD GV Water boiler series 3 - manualItem Description• Installation • Start-Up• Parts • Maintenance Figure 35 Section assemblyPart number 550-141-850/0699 XIId Replacement parts - jacket assembly GOLD GV Water boiler series 3 — manualItem Description• Installation • Start-Up• Parts • Maintenance Figure 36 Jacket assemblyPart number 550-141-850/0699 XIIe Replacement parts — Blower assembly Table 8 Blower assemblyGOLD GV Water boiler series 3 — manual ItemInstallation Start-Up Parts Maintenance Figure 37 Blower assemblyPart number 550-141-850/0699 Vent starter tee — not includedXIIf Replacement parts — trim assembly Table 9 Trim assemblyGOLD GV Water boiler series 3 - manual Item• Installation • Start-Up• Parts • Maintenance Figure 38 Trim assemblyPart number 550-141-850/0699 85048XIIg Replacement parts — interior panel GOLD GV Water boiler series 3 — manualItem Description• Installation • Start-Up• Parts • Maintenance FigureInterior panel Part number 550-141-850/0699XIII Dimensions and ratings GOLD GV Water boiler series 3 — manual• Installation • Start-Up• Parts • Maintenance Table 11 Boiler dimensional data see FigureCrate dimensions weightGOLD GV Water boiler - Series Weil-McLain 500 Blaine Street Michigan City, IN