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Weil-McLain GOLD DV WATER BOILER manuel d'utilisation

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Table des matières du manuel d’utilisation

  • Page 1

    GOLD GOLD GOLD GOLD GOLD P art No. 550-141-850/0699 W ater boiler — Series 3 GV GV GV GV GV Boiler manual • Installation • Start -Up • Maintenance P arts This manual must only be used by a qualified heating installer/ service technician . Failure to comply could result in severe personal injury , death or substantial property damage.[...]

  • Page 2

    Part number 550-141-850/0699 2 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual ① Control module The GCM control module responds to signals from the room thermostat, air pressure switch, inlet[...]

  • Page 3

    3 Part number 550-141-850/0699 Ž Installation • Star t-U p • Parts • Maintenanc e 85001 a b c d e supply to system retur n from system com b ustion air in le t fittin g flue outl et gas valv e (see w ar ning, ri ght) f g h i pressure/temperatur e gauge fluewa y inspecti on por t cover sensor hose trap manual air vent j relief v alve T h i sb[...]

  • Page 4

    Part number 550-141-850/0699 4 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual The following defined terms are used throughout this manual to bring attention to the presence of hazards of vario[...]

  • Page 5

    5 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Failure to adhere to the guidelines on this page can result in severe personal injury , death or substantial pro pert y damage. When servicing boiler — • T o av oid electric sho ck, disconnect electrical supply befor e performing maintenance. • T o av [...]

  • Page 6

    Part number 550-141-850/0699 6 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Contents Contents Summary Pages I . Prepar e boiler location • V er ify code compliance. Chec k f or high altitu[...]

  • Page 7

    7 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Contents Contents Summary Pages VII .S t a r t - u p • Deter mine water treatment needs, if any . Obtain correct antifreeze if freeze protection required. Check f or gas leaks (hav e propane odorant v erified b y supplier). Fill system and purge air . Read[...]

  • Page 8

    Part number 550-141-850/0699 8 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual P repare boiler location — overview Overview of this section ❏ V erify the boiler installation will meet all a[...]

  • Page 9

    9 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e • Local, state, provincial, and national codes, laws, regulations and ordinances. • National Fuel Gas Code, ANSI Z223.1- latest edition. • Standard for C ontrols and Sa fety D evices for Aut omatically Fired Boilers, ANSI/ASME CSD-1, when required. •[...]

  • Page 10

    Part number 550-141-850/0699 10 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Large space The boiler space must be at least as big as shown in Figure 1 to qualify as a large space . • Air o[...]

  • Page 11

    11 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Figure 2 Small space — installation with less clearance than Figure 1 – BUT – no less than below ; air openings for combustion/ventilation must be as shown below even for direct vent system. Boile r top Boile r side Fro nt Fr o nt 10" min 1"[...]

  • Page 12

    Part number 550-141-850/0699 12 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual P repare boiler location — vent system Vent system The GV boiler requires a special vent system, designed for p[...]

  • Page 13

    13 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e P repare boiler location — contamination Air contamination Please review the following information on potential combustion air contamination problems. Products to avoid Areas likely to have contaminants Spray cans c ontaining chloro/fluor ocarb ons Dr y c[...]

  • Page 14

    Part number 550-141-850/0699 14 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual P repare boiler location — air openings GV combustion air options Using inside air — non-direct vent The GV b[...]

  • Page 15

    15 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e GV in small space (less than Fig. 1) — alone For all vent/air situations, whether air is taken from inside or outside, provide two openings, each with minimum free area of: 1 square inch per 1,000 Btuh of GV input . The openings must be within 6 inches of[...]

  • Page 16

    Part number 550-141-850/0699 16 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual P repare boiler — overview ❏ Leave the boiler on its skid until installation site is ready and boiler prep is[...]

  • Page 17

    17 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e 85002 The v ent starter tee is NO T supplied with the boiler . Obtain this part as a separ ate purchase from y our W eil -M c Lain wholesaler . The ve nt star ter tee sho w n is for Saf-T V ent ® . U se only th e vent t ee made for the vent system y ou are[...]

  • Page 18

    Part number 550-141-850/0699 18 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual P repare boiler — orifice plate The correct orifice plate must be used. Failure to do so will result in severe [...]

  • Page 19

    19 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e GVX PROP GVX PROP GVX PROP Install pla te with red side (p ropane) o r plain side (natural) . against the blower housing Orifice pl ate after bendi ng along score mark. This makes the plate identific ation reada ble after installa tion. 85004b GVX PROP GVX [...]

  • Page 20

    Part number 550-141-850/0699 20 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual P repare boiler — high altitude kit When required When required When required When required When required For i[...]

  • Page 21

    21 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Figure 5c Air pressure switch mounting and sensor hoses — altitudes above 5, 500 feet ON L Y Jacket left side panel Interi or panel (2) 10-32 x 3/ 8" Phillip s/hex screws 85052 Boiler to p Whi t e hose Red hose[...]

  • Page 22

    Part number 550-141-850/0699 22 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual P repare boiler — place in position Boiler is heavy and contains some sheet metal parts which may have sharp ed[...]

  • Page 23

    23 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Clip ship ping strap Insta ll jacket rear panel with (4 ) screws , #10 x 3/8" Care fully ro tate boiler onto base rail leg s as show n 85003 RO T A TE RO T A TE Figure 6 Rotating boiler into position, removing skid and installing jacket rear panel[...]

  • Page 24

    Part number 550-141-850/0699 24 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual P repare boiler — pressure test P erform hydrostatic pressure test Pressure test boiler before attaching water [...]

  • Page 25

    25 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e 85007 T o fill/drain Figure 7 Piping connections for hydrostatic test[...]

  • Page 26

    Part number 550-141-850/0699 26 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual W ater piping — overview III a ❏ Select suggested piping from the following table, based on the type of syste[...]

  • Page 27

    27 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e W ater piping — relief valve 85008 Figure 8 Install and pipe relief valve T o av oid water damage or scalding due t o valve operation, a metal discharge line must be connected to relief valve outlet and run to a safe place of disposal . T e rminate the di[...]

  • Page 28

    Part number 550-141-850/0699 28 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual W ater piping — boiler connections Supply & return connections Always connect supply and return connections[...]

  • Page 29

    29 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e 85010 T o cold fill Figure 9 Piping to single-zone system using diaphragm- or bladder-type expansion tank. Boiler connections are 1" NPT (supply from 1" tee, return to 1" system circulator flange). 1 Relief valve discharge piping — see page[...]

  • Page 30

    Part number 550-141-850/0699 30 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual W ater piping — all systems III d Zoning with circulators Zoning with zone valves The GV internal system circul[...]

  • Page 31

    31 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e W ater piping — baseboard system III e Figure 11a Baseboard system (finned tube or cast iron) — zone valve zoning Zone 2 Zone 1 85013a Cold wa ter fill GV B oiler Figure 11b Baseboard system (finned tube or cast iron) — circulator zoning Zone 2 Zone 1[...]

  • Page 32

    Part number 550-141-850/0699 32 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual W ater piping — radiator system III f Figure 12a Radiator system — zone-valve zoning Zone 2 Zone 1 85013b Col[...]

  • Page 33

    33 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e W ater piping — single-zone radiant or heat pump system III g Figure 13 Single-zone radiant heating or heat pump system 85015a Loa d Cold water fill GV B oiler 12" max Legend 1 Boiler isolation valves 2 Automatic air vent (with diaphragm-type expansi[...]

  • Page 34

    Part number 550-141-850/0699 34 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Figure 14a Manual bypass; fixed temp operation only Zone 2 Zone 1 85015b Cold water fill GV B oiler 12" max [...]

  • Page 35

    35 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e W ater piping — snow melt system III i Figure 15b Auto return temp regulation; for outdoor reset or fixed temp Heating zone(s) 85016 Cold water fill GV B oiler 12" max Snow melt heat exchanger Figure 15a Manual bypass valves; for fixed temp operation[...]

  • Page 36

    Part number 550-141-850/0699 36 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual W ater piping — water chiller systems IIIj Figure 16 Installing GV boiler in system with water chiller Wa t e r[...]

  • Page 37

    37 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e V enting and combustion air IV Install vent piping and air piping (if used) p er appropriat e V ent supplement included in boiler env elope assembly . Ref e r t o V ent supplement and to manual Section I regarding req uirements fo r : • vent system • co[...]

  • Page 38

    Part number 550-141-850/0699 38 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Gas piping V Connecting gas supply piping to boiler 5. Use pipe dope compatible with propane gases . Apply sparin[...]

  • Page 39

    39 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Outl et he x fitting Mani f ol d Service valve (by others) Grou nd joint union (by others) ½ " N PT Nipple le ngth must provide at least 3 inches bet ween the cap and tee, per ANSI Z223.1. Drip le g (by others) Blower housing cover Blower housing cove[...]

  • Page 40

    Part number 550-141-850/0699 40 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Field wiring VI Electrical installation must comply with: National Electrical Code and any other national, state,[...]

  • Page 41

    41 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Field wiri ng Factory wiring Service switch (not provided) Junction box, boiler le ft side Thermostat leads, through jacke t left side Service switch (not provided) Thermostat or end switch (not provided) Thermostat or end switch (not provided) Black White [...]

  • Page 42

    Part number 550-141-850/0699 42 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Start -up — overview VII a ❏ Determine if water treatment will be needed to compensate for water hardness or [...]

  • Page 43

    43 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Start -up — preparation (cont.) VIIb V erify gas/air orifice plate The proper orifice plate must be used. Failure to do so will cause severe personal injury , death or substantial property damage. 1 . Remove the jacket front panel. 2 . Read the boiler siz[...]

  • Page 44

    Part number 550-141-850/0699 44 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Start -up — read Section IX VII c Boiler sequence of operation Manual Section IX contains information about the[...]

  • Page 45

    45 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Figure 19 Check for igniter glow by looking into observation port on front of blower housing. Observation port 85034 Start -up — if boiler doesn ’ t start . . . VII e Start -up — operate boiler (cont.) VII d 1 . Loose connections, blown fuse or servic[...]

  • Page 46

    Part number 550-141-850/0699 46 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Start -up — altitude over 5,500 feet ONL Y VII f Apply the following only when: • Altitude is over 5,500 feet[...]

  • Page 47

    47 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Figure 21 Carefully connect manometer to gas valve as shown, following instructions on opposite page. At Least 6 Inches Mani fo ld Cap on adjustment tower Gas contr ol vent ta p Gas control outl et pressure tap — Remove allen screw from gas control and in[...]

  • Page 48

    Part number 550-141-850/0699 48 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Check - out procedure — overview VIII a Check - out procedure — checklist VIIIb ❏ P erform the checklist f [...]

  • Page 49

    49 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e return to 0 V A C. Contr ol will attempt ig nition two mor e t imes, incr easing ig niter time to 30 seconds for these attempts. The control will then lockout, flashing the POWER and FLAME lights. e . T o restart system, follow Lighting instructions o n boi[...]

  • Page 50

    Part number 550-141-850/0699 50 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Operation — overview IX a ❏ The GCM (control module) is equipped with five indicator lights, used to show nor[...]

  • Page 51

    51 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Operation — sequence IXb 1. Standby W aiting for ca ll for heat · 2. Call for heat · · Circulator on Blower on 3. Limit circuit · · Limit controls cl osed Block switch contacts closed 4. Pressure circu it · · Pr essure switch c ontacts closed Ignit[...]

  • Page 52

    Part number 550-141-850/0699 52 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Operation — wiring diagrams IXb 120 V AC 24 V AC Control module low voltage section Control module 120 V AC sec[...]

  • Page 53

    53 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e POWER TST A T CIRC LIMIT PRES SWIT CH FLAME Field wiring Factory wiring Service switch (not provided) Junction box, boiler left sid e Thermostat leads, through jacket left sid e Service switch (not provided) Thermostat or end switch (not provided) Thermosta[...]

  • Page 54

    Part number 550-141-850/0699 54 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Operation — lighting instructions IXc Figure 25 Lighting instructions for boiler equipped with Robertshaw model[...]

  • Page 55

    55 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Figure 26 Lighting instructions for boiler equipped with White-Rodgers model 36E gas valve FOR YOUR SAFETY READ BEFORE OPERA TING OPERA TING INSTRUCTIONS TO TURN OFF GAS TO THE APPLIANCE • Do not try to light any appliance. • Do not touch any electric s[...]

  • Page 56

    Part number 550-141-850/0699 56 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Service and maintenance — overview Xa ❏ R e v iew T able 4 with the owner to advise of the nee d for annual s[...]

  • Page 57

    57 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Service technician (see following pages for instructions) Owner maintenance (see following pages for instructions) A NNNUAL START - UP Inspect: • Any problems reported by owner • Boiler area • Air openings • Flue gas vent • Boiler heating surfaces[...]

  • Page 58

    Part number 550-141-850/0699 58 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Service & maintenance — annual start -up Xc Annual start-up only by qualified service technician The boiler[...]

  • Page 59

    59 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Water piping 1 . Check the boiler interior piping and all system piping for signs of leaks. 2 . Repair any leaks before proceeding. Eliminate all system leaks . Continual fresh makeup water will reduce boiler life. Minerals can build up in sections, reducin[...]

  • Page 60

    Part number 550-141-850/0699 60 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Gas piping 1 . Sniff near floor and around boiler area for any indication of a gas leak . 2. T est gas piping usi[...]

  • Page 61

    61 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Expansion tank 1 . Expansion tanks provide space for water to move in and out as the heating system water expands due to tempe r ature increase or c ontracts as the water cools. T anks may be open-, closed- or diaphragm- or bladder-type. See Section III of [...]

  • Page 62

    Part number 550-141-850/0699 62 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Figure 30 Relief valve Boiler relief valve 1 . Inspect the relief valve and lift the lever to verify flow as in t[...]

  • Page 63

    63 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Service & maint. — special procedures Xd Condensate drain line check valve kit The service procedures listed in Section IXc of this manual must only be performed by a qualified boiler service technician. Failure to comply could res ult in se ver e per[...]

  • Page 64

    Part number 550-141-850/0699 64 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Service & maint. — special proced. (cont.) Xd Cleaning boiler heating surfaces The service procedures liste[...]

  • Page 65

    65 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e M O D E L 3 6 C 9 8 T Y P E 3 0 3 2 4 V 6 0 H Z 8 A M P S E 2 0 M A X P R E S S U R E ½ P S I G 9 6 4 7 N E C R E G - 1 “ W C P IL OT V E N T P R E S S TA P 85040 Red pressure switch hose White pressure switch hose Inlet air hose and clamps Blower suppor[...]

  • Page 66

    Part number 550-141-850/0699 66 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual T roubleshooting — overview XI a ❏ Section XIb — troubleshooting procedures. ❏ Section XIc — procedure [...]

  • Page 67

    67 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e T roubleshooting — procedures XIb Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Never jumper (bypass) any device except for momentary testing as outlined in T roubleshooting chart[...]

  • Page 68

    Part number 550-141-850/0699 68 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Checking the air pressure switch Do not use manometer as shown in Figure 33 to test gas valve outlet pressure. Wh[...]

  • Page 69

    69 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e T roubleshooting — servicing tips XI d Igniter W ait se veral minut es unt il igniter cools down before attempting replacement. Failure to do so will cause severe personal inj ur y . 1 . Disconnect igniter from igniter wiring harness and remov e ig niter [...]

  • Page 70

    Part number 550-141-850/0699 70 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual T roubleshooting — control module XI e Control Module Make sure ground wiring is installed per wiring diagram. [...]

  • Page 71

    71 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Indica tor lights POWER TST A T CIRC LIMIT PRES SWIT CH FLAME 120 V AC IN 120 V AC IN 120 V AC H 120 V AC H 24 V AC 120 V AC H 120 V AC H Red wires to pressure switch Blue wires t o gas valve Y e ll ow wire s to limit co ntrol and block temp switch Black wi[...]

  • Page 72

    Part number 550-141-850/0699 72 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Symptom Common Causes Possible Corrections Rapid cycling — boiler turns on and of f frequently Ther mostat inst[...]

  • Page 73

    73 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Symptom Common Causes Possible Corrections Popping or percolating noise heard in boiler Mineral deposits in sections due to constant u se of makeup water Call qualified ser vice technician to de-lime boiler , if necessar y . In some cases, deposits will be [...]

  • Page 74

    Part number 550-141-850/0699 74 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual T roubleshooting — GCM lights XI g CHART 1 — Troubleshooting POWER light status Electrical shock hazard — W[...]

  • Page 75

    75 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Electrical shock hazard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions. Failure to follow instructions could result in severe personl injury, death or substantial property damage. CHART 2 — TSTAT CIRC & POWER lights flashing •[...]

  • Page 76

    Part number 550-141-850/0699 76 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual T roubleshooting — GCM lights (continued) XI g CHART 3 — LIMIT & POWER lights flashing Electrical shock h[...]

  • Page 77

    77 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e CHART 4 — PRES SWITCH & POWER lights flashing Electrical shock hazard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. B[...]

  • Page 78

    Part number 550-141-850/0699 78 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual T roubleshooting — GCM lights (continued) XI g CHART 5 — FLAME & POWER lights flashing Electrical shock h[...]

  • Page 79

    79 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e • Remove CIRCULATORS plug ( Figure 34, Item 4 ) from plug receptacle of control module. • Place voltmeter leads across the 120 VAC N and 120 VAC H pins of the CIRCULATORS receptacle on the side corresponding to the circulator not operating. Does the vol[...]

  • Page 80

    Part number 550-141-850/0699 80 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual CHART 7 — LIMIT light flashing and POWER light on steady • This is not a lockout mode. The control module sho[...]

  • Page 81

    81 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e CHART 8 — Insufficient heat or no heat to system ( POWER light on steady) Electrical shock hazard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions. Failure to follow instructions could result in severe personl injury, death or substan[...]

  • Page 82

    Part number 550-141-850/0699 82 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Replacement parts — overview XII a ❏ Accessory bag assembly (shipped with boiler) ❏ Section assembly (boile[...]

  • Page 83

    83 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Replacement parts — accessory bag XIIb Item number Description W eil-McLain part number Quantity Remarks 1 W a te r trim bag asse mbly #2 542-200-309 1 2 Nipple, BK ¾ x 3.00 561-326-405 1 Relief v alve thru jack et 3 Nipple, BK 1 x 3.00 561-326-515 1 T e[...]

  • Page 84

    Part number 550-141-850/0699 84 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Item number Description Model Weil-McLain part number 1 Block assembly, includes: Front section, intermediate sec[...]

  • Page 85

    85 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e 85041 Figure 35 Section assembly[...]

  • Page 86

    Part number 550-141-850/0699 86 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Replacement parts — jack et assembly XII d T able 7 Jacket assembly Item number Description Model Weil-McLain p[...]

  • Page 87

    87 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Figure 36 Jacket assembly 85042[...]

  • Page 88

    Part number 550-141-850/0699 88 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Replacement parts — Blower assembly XII e T able 8 Blower assembly Item number Description Model W eil-McLain p[...]

  • Page 89

    89 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Figure 37 Blower assembly 85043 Ve n t s t a r t e r tee — not inclu ded[...]

  • Page 90

    Part number 550-141-850/0699 90 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Replacement parts — trim assembly XII f T able 9 T rim assembly Item number Description Weil-McLain part number[...]

  • Page 91

    91 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Figure 38 T rim assembly 85048 SY STEM[...]

  • Page 92

    Part number 550-141-850/0699 92 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Replacement parts — interior panel XII g Item number Description Weil-McLain part number 1 Interior panel with [...]

  • Page 93

    93 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e Figure 39 Interior panel 85046[...]

  • Page 94

    Part number 550-141-850/0699 94 GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual Dimensions and ratings XIII 85049 L Item numb er Description 1 1" NPT Supply 2 1" NPT Retur n 3 Combina[...]

  • Page 95

    95 Part number 550-141-850/0699 • Installation • Star t-U p • P ar ts • Maintenanc e T able 11 Boiler dimensional data (see Figure 40) T able 12 Boiler ratings Boiler model Supply (in. NPT) Return (in. NPT) Length L (inches) Gas connection size (Note 1) (in. NPT) Crate dimensions (outside measurement, inches) Approx. shipping weight (pounds[...]

  • Page 96

    Part number 550-141-850/0699 96 GOLD GV W GOLD GV W GOLD GV W GOLD GV W GOLD GV W ater boiler — Series 3 ater boiler — Series 3 ater boiler — Series 3 ater boiler — Series 3 ater boiler — Series 3 W eil-McLain 500 Blaine Street Michigan City , IN 46360-2388 http://www .weil-mclain.com[...]