Name: Weil-McLain Gold GV
Brand: Weil-McLain
Rating: 4 (1 reviews)

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GOLDGOLD

GOLD

Part No. 550-141-856/0703

Water Boiler — Series 4

GVGV

Boiler Manual

• Installation

• Start-Up

• Maintenance

Parts

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.

How It Works2
Parts Overview2
Air Pressure Switch2
Water Temperature Sensor2
Product View3
Hazard Definitions4
Please Read before Proceeding4
Warnings5
When Servicing Boiler5
Boiler Operation5
Boiler Water5
Content6
Prepare Boiler Location8
Codes & Altitude9
Clearances10
Flooring and Foundation11
Residential Garage Installation11
Vent System12
Removing from Existing Vent12
GV Special Vent System12
Vent Termination and Combustion Air Supply12
Air Contamination13
GV Combustion Air Options14
Sizing Air/Ventilation Openings14
Direct Exhaust Installations — GV Without Other Gas Appliances14
Air Opening Requirements When Direct Exhaust Venting14
Direct Vent Installations — GV Without Other Gas Appliances15
Special Considerations — Direct Exhaust or Direct Vent15
Exhaust Fans and Air Movers15
Motorized Air Dampers15
Prepare Boiler16
Vent Starter Tee & Drain16
Install Condensate Trap Hose16
Orifice Plate18
Checking and Replacing Gas/Air Orifice Plate19
High Altitude Kit20
Install High Altitude Air Pressure Switch20
Check Gas Valve Outlet Pressure20
Position Boiler22
Fill and Pressure Test24
Drain and Remove Fittings24
Perform Hydrostatic Pressure Test24
Piping Connections for Hydrostatic Test25
Water Piping26
Install Relief Valve27
Boiler Connections28
Supply & Return Connections28
Air Separator28
Expansion Tank28
Backflow Preventer28
Piping to Single-Zone System Using Diaphragm/Bladder-Type Tank29
Piping Closed-Type Expansion Tank29
Zoning with Circulators30
Zoning with Zone Valves30
Additional Components30
Low Water Cutoff Device30
Baseboard System Piping31
Radiator System Piping32
Single-Zone Radiant or Heat Pump System33
Adjust Balancing Valves33
Multi-Zone Radiant Heating System Piping34
Outdoor Reset Control34
Piping Snow Melt Systems/Combination Snow Melt/Space Heating Systems35
Manual Bypass Valves35
Auto Return Temp Regulation35
Water Chiller Systems36
Venting and Combustion Air37
Connecting Gas Supply Piping to Boiler38
Natural Gas38
Propane Gas38
V Gas Piping38
Gas Supply Connection to GV Boiler Gas Manifold39
Pipe Capacity for 0.60 Specific Gravity Natural Gas39
Field Wiring40
Wiring Connections40
Field Wiring Connections Diagram41
Start-Up42
Freeze Protection42
Verify Gas/Air Orifice Plate43
Check for Gas Leaks43
Fill the System with Water43
Inspect System Water Piping43
Start up44
To Operate Boiler44
Final Checks before Starting44
Check System and Boiler44
Start the Boiler44
If Boiler Doesn't Start45
Check for Igniter Glow45
Start-Up — Altitude over 5,500 Feet ONLY46
Connect and Adjust Manometer46
Check Gas Control Set Point46
Connect Manometer to Gas Valve47
Check-Out Procedure48
Installation and Service Certificate49
Operation50
Ignition Control Module Sequence of Operation — Status Lights51
Ladder Wiring Diagram52
Schematic Wiring Diagram53
Lighting Instruction54
To Turn off Gas to the Appliance54
Service and Maintenance55
Service and Maintenance Schedules56
Annual Start-Up - Inspection57
Annual Start-Up - Service59
Annual Start-Up Procedure59
Annual Start-Up — Check/Test60
Temperature Mixing System Check60
Air Vents and Air Elimination Check60
Limit Controls and Cutoffs Check60
Expansion Tank Check61
Gauges Check61
Igniter Check61
Igniter Observation Port in Blower View61
Boiler Relief Valve Check62
Review with Owner62
Service and Maintenance - Special Procedures63
Condensate Drain Line Check Valve Kit63
Cleaning Boiler Heating Surfaces64
To Remove the Blower Assembly64
To Clean Heating Surfaces64
Replace Blower Assembly64
Blower Housing Removal Procedure65
Troubleshooting66
Before Troubleshooting67
Checking the Air Pressure Switch68
Troubleshooting Air Pressure Reading68
Igniter - Servicing Tips69
Gas Valve - Servicing Tips69
Blower Housing - Servicing Tips69
Control Module Troubles70
GCM (Control Module) Harness Plug Receptacle and Indicator Lights71
Troubleshooting — Common Problems72
Rapid Cycling — Boiler Turns on and off Frequently72
Frequent Release of Water through Relief Valve72
Black Water Condition72
Popping or Percolating Noise Heard in Boiler73
Metal Flakes Found in Vent Outlet/Vent Starter Tee — Corrosion73
Some Radiators or Baseboard Units Do Not Heat or Are Noisy73
Troubleshooting Power Light Status74
TSTAT CIRC & Power Lights Flashing75
Limit and Power Lights Flashing76
PRES Switch and Power Lights Flashing77
Flame and Power Lights Flashing78
TSTAT CIRC Light Flashing and Power Light on Steady79
Limit Light Flashing and Power Light on Steady80
Insufficient Heat or no Heat to System (POWER Light on Steady)81
Replacement Parts Overview82
Handling Ceramic Fiber and Fiberglass Materials82
Removal of Combustion Chamber Lining or Base Panels82
Removal/Installation of Fiberglass Wool82
Accessory Bag Contents83
Replacement Parts - Section Assembly84
Section Assembly View85
Replacement Parts — Jacket Assembly86
Jacket Assembly View87
Replacement Parts — Blower Assembly88
Blower Assembly View89
Replacement Parts — Trim Assembly90
Trim Assembly View91
Replacement Parts — Interior Panel92
Interior Panel View93
Dimensions and Ratings94

Weil-McLain Gold GV User Manual

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Brand	Weil-McLain
Model	Gold GV
Category	Boiler
Language	English