Weil-McLain 550-141-850/0599 - Manuals

Page 3 - GOLD; Water boiler — Series 3

3 Part number 550-141-850/0699 Ž Installation • Start-Up • Parts • Maintenance 85001 a b c d e supply to system return from system combustion air inlet fitting flue outlet gas valve (see warning, right) f g h i pressure/temperature gauge flueway inspection port cover sensor hose trap manual air vent...

Page 4 - Hazard definitions; Please read before proceeding; Table of contents

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 bringattent...

Page 8 - Prepare boiler location —; Overview of this section; Ia

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 Prepare boiler location — overview Overview of this section ❏ Verify the b...

Page 9 - Ib; Installations must

9 Part number 550-141-850/0699 • Installation • Start-Up • Parts • Maintenance • Local, state, provincial, and national codes, laws, regulations and ordinances. • National Fuel Gas Code, ANSI Z223.1- latest edition. • Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASM...

Page 10 - Ic

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 inFigure 1 ...

Page 11 - Flooring and foundation; Residential garage installation

11 Part number 550-141-850/0699 • Installation • Start-Up • Parts • Maintenance Figure 2 Small space — installation with less clearance than Figure 1 – BUT – no less than below ; air openings for combustion/ventilation must beas shown below even for direct vent system. Boiler top Boiler side Fr o n ...

Page 12 - Removing from existing vent

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 Prepare boiler location — vent system Vent system The GV boiler requires ...

Page 13 - Air contamination; Ie

13 Part number 550-141-850/0699 • Installation • Start-Up • Parts • Maintenance Prepare boiler location — contamination Air contamination Please review the following information on potentialcombustion air contamination problems. Products to avoid Areas likely to have contaminants Spray cans containi...

Page 14 - GV combustion air options; Sizing air openings; GV with other appliances; GV without other appliances; If

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 Prepare boiler location — air openings GV combustion air options Using in...

Page 15 - Special considerations

15 Part number 550-141-850/0699 • Installation • Start-Up • Parts • Maintenance GV in small space (less than Fig. 1) — alone For all vent/air situations, whether air is taken from inside or outside, providetwo openings, each with minimum free area of: 1 square inch per 1,000 Btuh of GV input . The o...

Page 16 - Install vent starter; IIa; Prepare boiler —; IIb

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 Prepare boiler — overview ❏ Leave the boiler on its skid until installati...

Page 18 - Check for correct; IIc

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 Prepare boiler — orifice plate The correct orifice plate must be used. Fa...

Page 21 - — altitudes above 5,500 feet ONLY

21 Part number 550-141-850/0699 • Installation • Start-Up • Parts • Maintenance Figure 5c Air pressure switch mounting and sensor hoses — altitudes above 5,500 feet ONLY Jacket leftside panel Interior panel (2) 10-32 x 3/8"Phillips/hex screws 85052 Boiler top White hose Red hose

Page 22 - Position boiler; IIe

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 Prepare boiler — place in position Boiler is heavy and contains some shee...

Page 24 - IIf

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 Prepare boiler — pressure test Perform hydrostatic pressuretest Pressure ...

Page 26 - Water piping —; IIIa; Overview of this

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 Water piping — overview IIIa ❏ Select suggested piping from the following...

Page 27 - IIIb; Install relief valve

27 Part number 550-141-850/0699 • Installation • Start-Up • Parts • Maintenance Water piping — relief valve 85008 Figure 8 Install and pipe relief valve To avoid water damage or scalding due to valve operation, a metal dischargeline must be connected to relief valve outlet and run to a safe place of...

Page 28 - Supply & return connections; IIIc; Backflow preventer

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 Water piping — boiler connections Supply & return connections Always ...

Page 30 - IIId

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 Water piping — all systems IIId Zoning with circulators Zoning with zone ...

Page 31 - IIIe; Baseboard system piping

31 Part number 550-141-850/0699 • Installation • Start-Up • Parts • Maintenance Water piping — baseboard system IIIe Figure 11a Baseboard system (finned tube orcast iron) — zone valve zoning Zone 2 Zone 1 85013a Cold water fill GV Boiler Figure 11b Baseboard system (finned tube orcast iron) — circul...

Page 32 - IIIf; Radiator system piping

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 Water piping — radiator system IIIf Figure 12a Radiator system — zone-val...

Page 33 - single-zone radiant or heat pump system; IIIg

33 Part number 550-141-850/0699 • Installation • Start-Up • Parts • Maintenance Water piping — single-zone radiant or heat pump system IIIg Figure 13 Single-zone radiant heating orheat pump system 85015a Load Cold water fill GV Boiler 12" max Legend 1 Boiler isolation valves 2 Automatic air vent...

Page 34 - IIIh; Multi-zone radiant heating

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 tempoperation only Zone 2 Zone 1 85015b C...

Page 35 - IIIi; Piping snow melt systems or

35 Part number 550-141-850/0699 • Installation • Start-Up • Parts • Maintenance Water piping — snow melt system IIIi Figure 15b Auto return temp regulation; foroutdoor reset or fixed temp Heating zone(s) 85016 Cold water fill GV Boiler 12" max Snow melt heat exchanger Figure 15a Manual bypass va...

Page 36 - IIIj; Water chiller systems

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 Water piping — water chiller systems IIIj Figure 16 Installing GV boiler ...

Page 37 - Venting and combustion air; IV

37 Part number 550-141-850/0699 • Installation • Start-Up • Parts • Maintenance Venting and combustion air IV Install vent piping and air piping (if used) per appropriate Vent supplement included in boiler envelope assembly. Refer to Vent supplement and to manual Section I regarding requirements for...

Page 38 - Gas piping; Connecting gas supply piping to boiler

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 comp...

Page 40 - Field wiring; Wiring connections

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 mustcomply with: National Electri...

Page 42 - overview; VIIa; preparation; VIIb; Verify water chemistry

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 VIIa ❏ Determine if water treatment will be needed to...

Page 43 - Verify gas/air orifice plate

43 Part number 550-141-850/0699 • Installation • Start-Up • Parts • Maintenance Start-up — preparation (cont.) VIIb Verify gas/air orifice plate The proper orifice plate must be used. Failure to do so will causesevere personal injur y, death orsubstantial property damage. 1. Remove the jacket front ...

Page 44 - read Section IX; VIIc; to operate boiler; VIId; Start the boiler

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 VIIc Boiler sequence of operation Manual Secti...

Page 45 - VIIe; operate boiler

45 Part number 550-141-850/0699 • Installation • Start-Up • Parts • Maintenance Figure 19 Check for igniter glow by looking into observationport on front of blower housing. Observation port 85034 Start-up — if boiler doesn’t start . . . VIIe Start-up — operate boiler (cont.) VIId 1. Loose connection...

Page 46 - altitude over 5,500 feet ONLY

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 ONLY VIIf Apply the following only wh...

Page 48 - VIIIa; Check-out procedure —; VIIIb; Check off steps as

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 VIIIa Check-out procedure — checklist VIII...

Page 50 - Operation —; IXa

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 IXa ❏ The GCM (control module) is equipped with five...

Page 51 - IXb; Steps

51 Part number 550-141-850/0699 • Installation • Start-Up • Parts • Maintenance Operation — sequence IXb 1. Standby Waiting for call for heat · 2. Call for heat ·· Circulator on Blower on 3. Limit circuit ·· Limit controls closed Block switch contacts closed 4. Pressure circuit ·· Pressure switch co...

Page 54 - IXc; FOR YOUR SAFETY READ BEFORE OPERATING

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...

Page 56 - Service and maintenance —; Xa

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 ❏ Review Table 4 with the owner to ...

Page 57 - Xb

57 Part number 550-141-850/0699 • Installation • Start-Up • Parts • Maintenance Service technician (see following pages for instructions) Owner maintenance (see following pages for instructions) A N NNUAL ST AR T - UP Inspect: • Any problems reported by owner• Boiler area• Air openings• Flue gas ven...

Page 58 - Service & maintenance —; Xc; by qualified service; inspect

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 qu...

Page 59 - service

59 Part number 550-141-850/0699 • Installation • Start-Up • Parts • Maintenance 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...

Page 62 - owner review

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 an...

Page 63 - special procedures; Xd; Condensate drain line check valve kit

63 Part number 550-141-850/0699 • Installation • Start-Up • Parts • Maintenance Service & maint. — special procedures Xd Condensate drain line check valve kit The service procedures listed inSection IXc of this manual must only be performed by a qualified boilerservice technician. Failure to com...

Page 64 - Cleaning boiler heating surfaces

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...

Page 66 - Troubleshooting —; XIa

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 Troubleshooting — overview XIa ❏ Section XIb — troubleshooting procedures...

Page 67 - XIb

67 Part number 550-141-850/0699 • Installation • Start-Up • Parts • Maintenance Troubleshooting — 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 ...

Page 68 - Checking the air pressure switch; XIc

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 ...

Page 69 - XId; Igniter; Blower Housing; Gas Valve

69 Part number 550-141-850/0699 • Installation • Start-Up • Parts • Maintenance Troubleshooting — servicing tips XId Igniter Wait several minutes until igniterc o o l s d o w n b e f o r e a t t e m p t i n greplacement. Failure to do so willcause severe personal injury. 1. Disconnect igniter from i...

Page 70 - XIe; Control Module

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 Troubleshooting — control module XIe Control Module Make sure ground wiri...

Page 72 - Symptom; XIf

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 o...

Page 74 - XIg

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 Troubleshooting — GCM lights XIg CHART 1 — Troubleshooting POWER light st...

Page 82 - Replacement parts —; XIIa

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 XIIa ❏ Accessory bag assembly (shipped with ...

Page 83 - XIIb

83 Part number 550-141-850/0699 • Installation • Start-Up • Parts • Maintenance Replacement parts — accessory bag XIIb Item number Description Weil-McLain part number Quantity Remarks 1 Water trim bag assembly #2 542-200-309 1 2 Nipple, BK ¾ x 3.00 561-326-405 1 Relief valve thru jacket 3 Nipple, BK...

Page 84 - XIIc

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 Itemnumber Description Model Weil-McLainpart number 1 Block assembly, inc...

Page 86 - XIId

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 — jacket assembly XIId Table 7 Jacket assembly Itemnumb...

Page 88 - XIIe

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 XIIe Table 8 Blower assembly Item num...

Page 90 - XIIf

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 XIIf Table 9 Trim assembly Itemnumber D...

Page 92 - XIIg

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 XIIg Itemnumber Description Weil-McLai...

Page 94 - Dimensions and ratings; XIII

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 Itemnumber Description 1 1" NPT S...