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Gold GV
Weil-McLain Gold GV User Manual
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GOLD GV W
GOLD GV W
GOLD GV W
GOLD GV W
GOLD GV W
ater Boiler — Series 4
ater Boiler — Series 4
ater Boiler — Series 4
ater Boiler — Series 4
ater Boiler — Series 4
Part number 550-141-856/0703
54
Operation — lighting instructions
IXc
Figure 25
Lighting instruction
53
55
Table of Contents
How It Works
2
Parts Overview
2
Air Pressure Switch
2
Water Temperature Sensor
2
Product View
3
Hazard Definitions
4
Please Read before Proceeding
4
Warnings
5
When Servicing Boiler
5
Boiler Operation
5
Boiler Water
5
Content
6
Prepare Boiler Location
8
Codes & Altitude
9
Clearances
10
Flooring and Foundation
11
Residential Garage Installation
11
Vent System
12
Removing from Existing Vent
12
GV Special Vent System
12
Vent Termination and Combustion Air Supply
12
Air Contamination
13
GV Combustion Air Options
14
Sizing Air/Ventilation Openings
14
Direct Exhaust Installations — GV Without Other Gas Appliances
14
Air Opening Requirements When Direct Exhaust Venting
14
Direct Vent Installations — GV Without Other Gas Appliances
15
Special Considerations — Direct Exhaust or Direct Vent
15
Exhaust Fans and Air Movers
15
Motorized Air Dampers
15
Prepare Boiler
16
Vent Starter Tee & Drain
16
Install Condensate Trap Hose
16
Orifice Plate
18
Checking and Replacing Gas/Air Orifice Plate
19
High Altitude Kit
20
Install High Altitude Air Pressure Switch
20
Check Gas Valve Outlet Pressure
20
Position Boiler
22
Fill and Pressure Test
24
Drain and Remove Fittings
24
Perform Hydrostatic Pressure Test
24
Piping Connections for Hydrostatic Test
25
Water Piping
26
Install Relief Valve
27
Boiler Connections
28
Supply & Return Connections
28
Air Separator
28
Expansion Tank
28
Backflow Preventer
28
Piping to Single-Zone System Using Diaphragm/Bladder-Type Tank
29
Piping Closed-Type Expansion Tank
29
Zoning with Circulators
30
Zoning with Zone Valves
30
Additional Components
30
Low Water Cutoff Device
30
Baseboard System Piping
31
Radiator System Piping
32
Single-Zone Radiant or Heat Pump System
33
Adjust Balancing Valves
33
Multi-Zone Radiant Heating System Piping
34
Outdoor Reset Control
34
Piping Snow Melt Systems/Combination Snow Melt/Space Heating Systems
35
Manual Bypass Valves
35
Auto Return Temp Regulation
35
Water Chiller Systems
36
Venting and Combustion Air
37
Connecting Gas Supply Piping to Boiler
38
Natural Gas
38
Propane Gas
38
V Gas Piping
38
Gas Supply Connection to GV Boiler Gas Manifold
39
Pipe Capacity for 0.60 Specific Gravity Natural Gas
39
Field Wiring
40
Wiring Connections
40
Field Wiring Connections Diagram
41
Start-Up
42
Freeze Protection
42
Verify Gas/Air Orifice Plate
43
Check for Gas Leaks
43
Fill the System with Water
43
Inspect System Water Piping
43
Start up
44
To Operate Boiler
44
Final Checks before Starting
44
Check System and Boiler
44
Start the Boiler
44
If Boiler Doesn't Start
45
Check for Igniter Glow
45
Start-Up — Altitude over 5,500 Feet ONLY
46
Connect and Adjust Manometer
46
Check Gas Control Set Point
46
Connect Manometer to Gas Valve
47
Check-Out Procedure
48
Installation and Service Certificate
49
Operation
50
Ignition Control Module Sequence of Operation — Status Lights
51
Ladder Wiring Diagram
52
Schematic Wiring Diagram
53
Lighting Instruction
54
To Turn off Gas to the Appliance
54
Service and Maintenance
55
Service and Maintenance Schedules
56
Annual Start-Up - Inspection
57
Annual Start-Up - Service
59
Annual Start-Up Procedure
59
Annual Start-Up — Check/Test
60
Temperature Mixing System Check
60
Air Vents and Air Elimination Check
60
Limit Controls and Cutoffs Check
60
Expansion Tank Check
61
Gauges Check
61
Igniter Check
61
Igniter Observation Port in Blower View
61
Boiler Relief Valve Check
62
Review with Owner
62
Service and Maintenance - Special Procedures
63
Condensate Drain Line Check Valve Kit
63
Cleaning Boiler Heating Surfaces
64
To Remove the Blower Assembly
64
To Clean Heating Surfaces
64
Replace Blower Assembly
64
Blower Housing Removal Procedure
65
Troubleshooting
66
Before Troubleshooting
67
Checking the Air Pressure Switch
68
Troubleshooting Air Pressure Reading
68
Igniter - Servicing Tips
69
Gas Valve - Servicing Tips
69
Blower Housing - Servicing Tips
69
Control Module Troubles
70
GCM (Control Module) Harness Plug Receptacle and Indicator Lights
71
Troubleshooting — Common Problems
72
Rapid Cycling — Boiler Turns on and off Frequently
72
Frequent Release of Water through Relief Valve
72
Black Water Condition
72
Popping or Percolating Noise Heard in Boiler
73
Metal Flakes Found in Vent Outlet/Vent Starter Tee — Corrosion
73
Some Radiators or Baseboard Units Do Not Heat or Are Noisy
73
Troubleshooting Power Light Status
74
TSTAT CIRC & Power Lights Flashing
75
Limit and Power Lights Flashing
76
PRES Switch and Power Lights Flashing
77
Flame and Power Lights Flashing
78
TSTAT CIRC Light Flashing and Power Light on Steady
79
Limit Light Flashing and Power Light on Steady
80
Insufficient Heat or no Heat to System (POWER Light on Steady)
81
Replacement Parts Overview
82
Handling Ceramic Fiber and Fiberglass Materials
82
Removal of Combustion Chamber Lining or Base Panels
82
Removal/Installation of Fiberglass Wool
82
Accessory Bag Contents
83
Replacement Parts - Section Assembly
84
Section Assembly View
85
Replacement Parts — Jacket Assembly
86
Jacket Assembly View
87
Replacement Parts — Blower Assembly
88
Blower Assembly View
89
Replacement Parts — Trim Assembly
90
Trim Assembly View
91
Replacement Parts — Interior Panel
92
Interior Panel View
93
Dimensions and Ratings
94
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Instructionsfor Use
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Weil-McLain Gold GV Specifications
General
Brand
Weil-McLain
Model
Gold GV
Category
Boiler
Language
English
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