GOLD GV Water boiler — Series 3 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. Part No.
GOLD GV Water boiler series 3 — manual How it works . . . ① Control module The GCM control module responds to signals from the room thermostat, air pressure switch, inlet water sensor and boiler limit circuit to operate the circulators, gas valve, igniter and blower. When a room thermostat calls for heat, the GCM starts the system circulator and blower. The GCM runs the blower long enough to purge the boiler flue passages, then turns on the igniter and lets it warm up.
Ž Installation • Start-Up • Parts • Maintenance GOLD GV Water boiler — Series 3 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 j Part number 550-141-850/0699 pressure/temperature gauge flueway inspection port cover sensor hose trap manual air vent relief valve 85001 This boiler uses a negative-pressureregulated gas valve, set for an outlet pressure approximately –0.20" w.c..
GOLD GV Water boiler series 3 — manual Please read before proceeding Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product. Indicates presence of hazards that will cause severe personal injury, death or substantial property damage. Indicates presence of hazards that can cause severe personal injury, death or substantial property damage.
• Installation • Start-Up • Parts • Maintenance Please read before proceeding Failure to adhere to the guidelines on this page can result in severe personal injury, death or substantial property damage. When servicing boiler — • To avoid electric shock, disconnect electrical supply before performing maintenance. • To avoid severe burns, allow boiler to cool before performing maintenance. Boiler operation — • Do not block flow of combustion or ventilation air to boiler.
GOLD GV Water boiler series 3 — manual Contents Contents I. Prepare boiler location II. Prepare boiler Pages • Verify code compliance. Check for high altitude requirements. Provide required clearances and accessibility. Plan vent and combustion air provisions. Check existing common vents to be sure they will work when old boiler is removed from system. 8 – 15 Leave boiler on its skid until preparation complete. Install vent starter tee. Inspect/replace if necessary the gas/air orifice.
• Installation • Start-Up • Parts • Maintenance Contents Contents Summary VII. Start-up • Determine water treatment needs, if any. Obtain correct antifreeze if freeze protection required. Check for gas leaks (have propane odorant verified by supplier). Fill system and purge air. Read Operating instructions, section IX, then start boiler. Check all piping and verify leak-free. Check gas valve outlet pressure (altitudes over 5,500 feet). Pages 42 – 47 VIII.
GOLD GV Water boiler series 3 — manual Ia Prepare boiler location — overview Overview of this section ❏ Verify the boiler installation will meet all applicable codes. ❏ If the boiler installation is at high altitude (over 5,500 feet) make sure to obtain and install the high altitude kit. Obtain the high altitude kit and review the instructions included. Note the venting restrictions and input reductions at altitudes over 5,500 feet.
• Installation • Start-Up • Parts • Maintenance Ib Prepare boiler location — codes & altitude Installations must follow these codes: • 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/ASME CSD-1, when required. • National Electrical Code. • For Canada only: CAN/CGA B149.1 or B149.2 Installation Code and C.S.A. C22.
GOLD GV Water boiler series 3 — manual Ic Prepare boiler location — clearances Clearance options: Figure 1 Large space Large space — minimum clearances between boiler and walls or obstructions as below; see Section Ie for minimum combustion/ventilation air opening sizing. The boiler space must be at least as big as shown in Figure 1 to qualify as a large space. • Air openings to a large space can be per manual Section Ie.
• Installation • Start-Up • Parts • Maintenance Figure 2 Flooring and foundation 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. Flooring The GV boiler is approved for installation on combustible flooring, but must never be installed on carpeting. TOP VIEW Do not install boiler on carpeting even if foundation is used.
GOLD GV Water boiler series 3 — manual Id Prepare boiler location — vent system Removing from existing vent Failure to follow all instructions following can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death. Correct by resizing to approach the minimum size as determined using the appropriate tables in Part 11 of that code. Canadian installations must comply with CAN/ CGA B149.1 or B149.2 Installation Code.
• Installation • Start-Up • Parts • Maintenance Ie Prepare boiler location — contamination Air contamination Please review the following information on potential combustion air contamination problems. Refer to Table 2 for products and areas which may cause contaminated combustion air. If the boiler is installed in any area likely to cause contamination, or if products which would contaminate the air cannot be removed, you must pipe combustion air to the boiler air intake.
GOLD GV Water boiler series 3 — manual If Prepare boiler location — air openings GV combustion air options Single air opening option Using inside air — non-direct vent The GV boiler can use inside air if no contaminants are present in the boiler space. A single air opening within 12 inches of the ceiling may be used where the GV boiler is installed in a large space (clearances per Figure 1) with other appliances.
• Installation • Start-Up • Parts • Maintenance 0 to 12" Each opening free area = 1 sq. inch per 1,000 Btuh Add air openings to outside if building is tight construction. Other appliances a— Air opening Air openings: GV in space with other appliances a Flue Air from inside building Air (direct vent) (optional) GV b 0 to 12" Each opening free area = 1 sq.
GOLD GV Water boiler series 3 — manual IIa Prepare boiler — overview Overview of this ❏ Leave the boiler on its skid until installation site is ready and boiler prep is complete per this section. section ❏ Install vent starter tee and condensate drain line. ❏ Inspect gas/air orifice plate to verify model size and gas markings agree with boiler and application. Install propane gas/air orifice for propane installations. ❏ Install high altitude kit for altitudes more than 5500 feet above sea level.
• Installation • Start-Up • Parts • Maintenance IIb Figure 4 Prepare boiler — vent starter tee & drain (cont.) Install vent starter tee and condensate drain hose before placing boiler. Screw hole and notch, located in base rail under vent outlet Base rail Insert CPVC elbow into bracket. Then attach bracket to base rail with screw as shown at left. 10-32 x 3/8" Vent starter tee — not included with boiler. See information below. The vent starter tee is NOT supplied with the boiler.
GOLD GV Water boiler series 3 — manual IIc Prepare boiler — orifice plate The correct orifice plate must be used. Failure to do so will result in severe Check for correct personal injury, death or substantial property damage. orifice plate and replace if necessary Natural gas: For natural gas installations, inspect the silver gas/air orifice plate marking. It must be the same as the boiler size. If the orifice plate is stamped with another size, obtain the correct plate from your wholesaler.
• Installation • Start-Up • Parts • Maintenance Figure 5b Checking and replacing gas/air orifice plate. For propane installations, replace silver plate with red/white propane plate. DO NOT use electric or pneumatic screwdrivers to remove or tighten the gas/air boss screws. Hand-tighten only, using manual screwdriver. Should the torque exceed 40 inch-pounds, the threaded holes could strip out, causing an inadequate seal of the orifice plate.
GOLD GV Water boiler series 3 — manual IId Prepare boiler — high altitude kit Obtain high altitude When required kit For installations at altitude more than 5,500 feet above sea level, a special high altitude air pressure switch is required. In addition, the gas valve outlet pressure setting must be checked, and adjusted if necessary, per the instructions in manual Section VIIf, altitude over 5,500 feet. Obtain the GV high altitude kit from your local WeilMcLain distributor.
• Installation • Start-Up • Parts • Maintenance — altitudes above 5,500 feet ONLY Figure 5c Air pressure switch mounting and sensor hoses Jacket left side panel White hose Red hose Interior panel (2) 10-32 x 3/8" Phillips/hex screws Boiler top 85052 Part number 550-141-850/0699 21
GOLD GV Water boiler series 3 — manual IIe Prepare boiler — place in position Position boiler After installing vent starter tee, inspecting (replacing if necessary) the gas/air orifice and installing the high altitude kit (if required), move the boiler near its position. Figure 6 shows the boiler with the front and top panels replaced. These panels may be left off if desired until the installation has been completed.
• Installation • Start-Up • Parts • Maintenance Figure 6 Rotating boiler into position, removing skid and installing jacket rear panel Carefully rotate boiler onto base rail legs as shown ROTATE ROTATE Install jacket rear panel with (4) screws, #10 x 3/8" Clip shipping strap Part number 550-141-850/0699 85003 23
GOLD GV Water boiler series 3 — manual IIf Prepare boiler — pressure test Perform hydrostatic pressure test 5. Slowly reopen drain valve (item 2) until test pressure of not more than 45 psi is reached on the pressure gauge. Pressure test boiler before attaching water or gas piping (except as noted below) or electrical supply. 6. Test at no more than 45 psi for no more than 10 minutes. Prepare boiler for test (Fig. 7) Do not leave boiler unattended.
• Installation • Start-Up • Parts • Maintenance Figure 7 Piping connections for hydrostatic test To fill/drain 85007 Part number 550-141-850/0699 25
GOLD GV Water boiler series 3 — manual IIIa Water piping — overview Overview of this ❏ Select suggested piping from the following table, based on the type of system in which you are installing the GV boiler. section ❏ Review boiler connections, pages 28 – 29 — information on supply and return connections at boiler and key system components (air separator and expansion tank). ❏ Review page 30, information applying to all systems.
• Installation • Start-Up • Parts • Maintenance IIIb Install relief valve Water piping — relief valve Refer to Figure 8 for location of the relief valve on the boiler. Install the relief with the spindle vertical in the ¾" tapping on top left of the back section, as shown. To avoid water damage or scalding due to valve operation, a metal discharge line must be connected to relief valve outlet and run to a safe place of disposal.
GOLD GV Water boiler series 3 — manual IIIc Water piping — boiler connections Supply & return connections Always connect supply and return connections to the boiler as shown in Figure 9. (Note in the following and in the suggested piping drawings in this manual that the expansion tank and air separator location will depend on the system piping.) Operating pressure of system, after temperature expansion above cold fill pressure, should not exceed 24 PSIG to avoid weeping of relief valve.
• Installation • Start-Up • Parts • Maintenance 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).
GOLD GV Water boiler series 3 — manual IIId Zoning with circulators Water piping — all systems The GV internal system circulator cannot be removed from the boiler for use as one of the zone circulators. It must remain as shipped from the factory to allow proper flow control inside the boiler. You will need a circulator for each zone. Size the common (primary) pipe for the combined flow of all circulators, or with a pipe cross-sectional area at least equal to the total areas of all zone supply pipes.
• Installation • Start-Up • Parts • Maintenance IIIe Water piping — baseboard system Figure 11a Baseboard system (finned tube or cast iron) — zone valve zoning Baseboard system piping Apply Figure 11a (zone-valve zoning) or 11b (circulator zoning) to systems using baseboard heaters. The heaters can be any baseboard style, including finned tube or cast iron. Zone 2 Zone 1 The boiler internal “System circulator” can be used to circulate most zone-valve zoned systems as shown in Figure 11a.
GOLD GV Water boiler series 3 — manual IIIf Water piping — radiator system Figure 12a Radiator system — zone-valve zoning Radiator system piping Apply Figure 12a (zone-valve zoning) or 12b (circulator zoning) to systems using standing cast iron radiators. This applies to gravity water systems and converted steam systems using columnar, tubular or recessed cast iron radiators.
• Installation • Start-Up • Parts • Maintenance IIIg Water piping — single-zone radiant or heat pump system Single-zone radiant heating or heat pump piping You may also apply the suggested piping of either Figure 14a or 14b if you want automatic supply temperature regulation or outdoor reset temperature control. Radiant heating systems and heat pump systems usually require system supply water temperatures below 130 °F.
GOLD GV Water boiler series 3 — manual IIIh Water piping — multi-zone radiant system Figure 14a Manual bypass; fixed temp operation only Zone 2 Multi-zone radiant heating system piping Multi-zone systems require automatic regulation of the system supply temperature because of widely varying load conditions. Figure 14a (zone-valve zoning) and Figure 14b (circulator zoning) show suggested piping for these systems.
• Installation • Start-Up • Parts • Maintenance IIIi Water piping — snow melt system Figure 15a Manual bypass valves; for fixed temp operation only Snow melt heat exchanger Piping snow melt systems or combination snow melt/ space heating systems Combination snow melt/space heating systems will have widely varying system return temperatures. So these systems require automatic return water temperature as shown in Figure 15a (zone-valve zoning) or Figure 15b (circulator zoning).
GOLD GV Water boiler series 3 — manual IIIj Water piping — water chiller systems Water chiller systems Figure 16 Installing GV boiler in system with water chiller Pipe the boiler and water chiller as shown in Figure 16. Expansion tank 12" max Balancing valve Install boiler, as shown, so chilled medium is piped in parallel with heating boiler. Use appropriate valves to prevent chilled medium from entering boiler. See Figure 16 for typical installation of balancing valve and check valve.
• Installation • Start-Up • Parts • Maintenance IV Venting and combustion air GV boiler must be vented and supplied with combustion and ventilation air as described in GV Series 3 Venting supplements packed in envelope assembly with boiler. Failure to do so will cause severe personal injury or death. Install vent piping and air piping (if used) per appropriate Vent supplement included in boiler envelope assembly.
GOLD GV Water boiler series 3 — manual V Gas piping Connecting gas supply piping to boiler Do not connect gas supply to boiler or attempt to operate boiler unless the correct orifice plate has been verified or installed in accordance with manual Section IIc. Except where otherwise instructed in this manual, do not attempt to measure or adjust the outlet pressure setting of the gas valve. The gas valve is factory set to a slight negative pressure, and is operated as a negative-pressure regulated valve.
• Installation • Start-Up • Parts • Maintenance Always use a wrench on the manifold to prevent it from twisting when installing or removing external gas piping. Failure to do so could damage the blower housing assembly, resulting in a leakage of Service valve (by others) Figure 17 Gas supply connection to GV boiler gas manifold Table 3 Pipe capacity for 0.
GOLD GV Water boiler series 3 — manual VI Field wiring Electrical installation must comply with: National Electrical Code and any other national, state, provincial or local codes or regulations. In Canada, C.S.A. C22.1 Canadian Electrical Code Part 1, and any local codes. Wiring must be N.E.C. Class 1. If original wiring as supplied with boiler must be replaced, use only type 90 °C wire or equivalent. Boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 70-latest edition.
• Installation • Start-Up • Parts • Maintenance Figure 18 Field wiring connections — service switch and thermostat (or end switch) provided by installer Field wiring 120 VAC Hot Service switch Neutral Ground (not provided) Thermostat or end switch (not provided) Service switch (not provided) Thermostat or end switch Factory wiring Ground screw Black White Green Wire nuts Black (not provided) Black Thermostat leads, through jacket left side Junction box, boiler left side 85028 For your
GOLD GV Water boiler series 3 — manual VIIa Start-up — overview ❏ Determine if water treatment will be needed to compensate for water hardness or pH. ❏ Obtain propylene/glycol antifreeze if freeze protection is required. Glycol must be propylene glycol only, and special requirements may apply when using glycol. ❏ Check for gas leaks (and verify propane odorant level). ❏ Fill system with water and purge air. Verify water piping is leak-free. ❏ Study boiler operating instructions, Section IX.
• Installation • Start-Up • Parts • Maintenance VIIb Start-up — preparation Verify 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 size written on the gas/air orifice label tab, verifying the correct size. See Figure 5b for details. 3. The orifice plate must be plain aluminum for natural gas. For propane gas, the exposed tab of the plate should be red.
GOLD GV Water boiler series 3 — manual VIIc Start-up — read Section IX Boiler sequence of operation Lighting instructions Manual Section IX contains information about the operation of the boiler and controls. Read this information, including the Sequence of operation diagram, to familiarize yourself with the normal operation of the control system. Note also the lockout conditions of the boiler control module, found on the control cover label.
• Installation • Start-Up • Parts • Maintenance VIId Figure 19 Start-up — operate boiler Check for igniter glow by looking into observation port on front of blower housing. (cont.) 2. Vent air from system using manual vents. Air in the system will interfere with circulation and cause heat distribution problems and noise. 3. Inspect vent system thoroughly. Check for gastight seal at every connection and seam. 4. Check around the boiler for gas odor following the procedure of Section VIIb of this manual.
GOLD GV Water boiler series 3 — manual VIIf Start-up — altitude over 5,500 feet ONLY Apply the following only when: • Altitude is over 5,500 feet above sea level. • You have obtained a high altitude kit (with tools needed) and installed high altitude air pressure switch per the instructions of manual Section IId. • Boiler has started correctly, following procedures on previous pages. Figure 20 Tools required for gas valve outlet pressure measurement You will need the tools shown in Figure 20.
• Installation • Start-Up • Parts • Maintenance Figure 21 Carefully connect manometer to gas valve as shown, following instructions on opposite page. Cap on adjustment tower Gas control outlet pressure tap — Remove allen screw from gas control outlet pressure tap and install hose barb as shown.
GOLD GV Water boiler series 3 — manual VIIIa Check-out procedure — overview Overview of this ❏ Perform the checklist following to ensure boiler is operating correctly. section ❏ Fill in the Installation and service certificate at the end of the checklist.
• Installation • Start-Up • Parts • Maintenance VIIIb Check-out procedure — checklist e. (cont.) return to 0 VAC. Control will attempt ignition two more times, increasing igniter time to 30 seconds for these attempts. The control will then lockout, flashing the POWER and FLAME lights. To restart system, follow Lighting instructions on boiler or in manual Section IX. (Control will reset after power has been off for at least 45 seconds.) ! Set limit control(s) to system temperature requirements.
GOLD GV Water boiler series 3 — manual IXa Operation — overview Overview of this ❏ The GCM (control module) is equipped with five indicator lights, used to show normal and problem situations. See Figure 22 for the normal sequence section of operation of the boiler and control, and the status of the lights at each stage. For explanation of the lockout conditions of the GCM lights, see manual Section X, Troubleshooting. ❏ Figure 23 shows the ladder wiring diagram for the GV series 3 boiler.
• Installation • Start-Up • Parts • Maintenance IXb Operation — sequence Figure 22 Ignition control module sequence of operation — status light indications POWER Steps TSTAT CIRC Call for heat? LIMIT PRESS SWITCH FLAME Timing (Following step 8, cycle goes back to step 1.) 1. Standby · Waiting for call for heat NO — YES — YES — YES 35 sec YES 6 sec YES — YES — NO 30 sec 2. Call for heat · · Circulator on Blower on 3.
GOLD GV Water boiler series 3 — manual IXb Operation — wiring diagrams Figure 23 Ladder wiring diagram 120 VAC Gnd Service switch (not provided) Igniter Electrical shock hazard — can cause severe injury or death. Disconnect power before installing or servicing. Blower motor All contacts are shown without power applied.
• Installation • Start-Up • Parts • Maintenance Schematic wiring diagram 120 VAC Hot Field wiring Figure 24 Service switch Ground Neutral (not provided) Thermostat or end switch (not provided) Service switch (not provided) Thermostat or end switch Plug-in connectors White Red Factory wiring Ground screw 120 VAC hot/neutral Low voltage (colors vary) Black White Green (not provided) Wire nuts Black Black Thermostat leads, through jacket left side Junction box, boiler left side Ground
GOLD GV Water boiler series 3 — manual IXc Figure 25 Operation — lighting instructions Lighting instructions for boiler equipped with Robertshaw model 7200DERN gas valve FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. C.
• Installation • Start-Up • Parts • Maintenance Figure 26 Lighting instructions for boiler equipped with White-Rodgers model 36E gas valve FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. C.
GOLD GV Water boiler series 3 — manual Xa Service and maintenance — overview Overview of this section ❏ Review Table 4 with the owner to advise of the need for annual start-up and service by a qualified technician. ❏ Review Table 4 with the owner, explaining the maintenance required and procedures to follow. ❏ The following pages of this section provide detailed instructions for each of the service and maintenance items given in Table 4.
• Installation • Start-Up • Parts • Maintenance Xb Service and maintenance — schedule Table 4 Service and maintenance schedules Service technician Owner maintenance (see following pages for instructions) (see following pages for instructions) ANNNUAL START-UP Inspect: • • • • • • • Any problems reported by owner Boiler area Air openings Flue gas vent Boiler heating surfaces Water piping Condensate drain system Service: • Check boiler area Daily • Check air openings • Check pressure gauge • Ch
GOLD GV Water boiler series 3 — manual Xc Service & maintenance — annual start-up Annual start-up only by qualified service technician The boiler should be inspected and started annually, at the beginning of the heating season, only by a qualified service technician. In addition, the maintenance and care of the boiler designated in Table 4 and explained on the following pages must be performed to assure maximum boiler efficiency and reliability.
• Installation • Start-Up • Parts • Maintenance Annual start-up — Water piping inspect 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, reducing heat transfer, overheating cast iron, and causing section failure. Do not use petroleum-based cleaning or sealing compounds in boiler system.
GOLD GV Water boiler series 3 — manual Xc Service & maint. — annual start-up (cont.) Annual start-up — Gas piping check/test 1. Sniff near floor and around boiler area for any indication of a gas leak. 2. Test gas piping using bubble test, per Section V of this manual, if there is any indication of a leak. Cold fill and operating pressures 1. While the system is cold, note the pressure reading on the boiler pressure/temperaure gauge. Verify that cold fill pressure is correct. 2.
• Installation • Start-Up • Parts • Maintenance Annual start-up — Expansion tank check/test 1. Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools. Tanks may be open-, closed- or diaphragm- or bladder-type. See Section III of this manual for suggested best location of expansion tanks and air eliminators. Open-type — Located above highest radiator or baseboard unit, usually in the attic or closet.
GOLD GV Water boiler series 3 — manual Xc Service & maint. — annual start-up Annual start-up — Boiler relief valve check/test 1. Inspect the relief valve and lift the lever to verify flow Figure 30 (cont.) Relief valve as in the following warnings, excerpted from a relief valve manufacturer’s warning label. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read manual Section IIIb before proceeding further.
• Installation • Start-Up • Parts • Maintenance Xd Service & maint. — special procedures 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 result in severe personal injury, death or substantial property damage. Figure 31 Condensate drain line check valve kit, installed — Refer to kit for detailed instructions. 1.
GOLD GV Water boiler series 3 — manual Xd Service & maint. — special proced. (cont.) Cleaning boiler heating surfaces The service procedures listed in Section IXc of this manual must only be performed by a qualified boiler service technician. Failure to comply could result in severe personal injury, death or substantial property damage. 1. If inspection of the boiler flueways indicates the presence of soot, clean the boiler heating surfaces using the following procedure.
• Installation • Start-Up • Parts • Maintenance Figure 32 Blower housing removal procedure Air pressure switch Blower motor wiring harness Blower support bracket Burner gasket (replace) Burner cone and ring assembly Igniter gasket (replace) NT VE MOD EL 24V 36C9 MAX60 HZ8 NE PR C RE ESSU 8 AM G - RE PS TYPE 1“ ½ 303 WC PS IG E2 0 9647 S ES PR OT PIL Igniter Gas/air orifice plate P TA Gas tubing Red pressure switch hose White pressure switch hose Inlet air hose and clamps 85040 Part number 550-1
GOLD GV Water boiler series 3 — manual XIa Troubleshooting — overview Overview of this ❏ Section XIb — troubleshooting procedures. section ❏ Section XIc — procedure for checking air pressure switch. ❏ Section XId — special servicing tips (for igniter, gas valve and blower housing). ❏ Section XIe — control module. ❏ Section XIf — common problems and possible solutions. ❏ Section XIg — troubleshooting GCM indicator light conditions.
• Installation • Start-Up • Parts • Maintenance XIb Troubleshooting — procedures 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 Troubleshooting charts. Severe personal injury, death or substantial property damage can result. The control module and boiler controls can malfunction if they get wet. Never try to use a control that has been flooded or wet.
GOLD GV Water boiler series 3 — manual XIc Troubleshooting — air pressure switch Checking the air pressure switch Do not use manometer as shown in Figure 33 to test gas valve outlet pressure. Where instructed in this manual to check gas valve outlet pressure, follow instructions carefully, particularly regarding connection of manometer. Manometer fluid will cause permanent damage to gas valve. Severe personal injury, death or substantial property damage can result. Check switch pressure setting 1.
• Installation • Start-Up • Parts • Maintenance XId Troubleshooting — servicing tips Igniter Wait several minutes until igniter cools down before attempting replacement. Failure to do so will cause severe personal injury. 1. Disconnect igniter from igniter wiring harness and remove igniter before removing blower assembly. 2. Replace igniter gasket if original gasket is frayed or damaged. 3. Igniter is fragile - handle with care. Do not touch igniter surface with bare hands.
GOLD GV Water boiler series 3 — manual XIe Troubleshooting — control module Control Module Make sure ground wiring is installed per wiring diagram. Good grounding is extremely important for proper operation. Solder or water splatter between plugs and circuit board can cause improper operation of control module. Place a shield over the boiler internal controls and components during installation. Failure to comply could result in severe personal injury, death or substantial property damage.
• Installation • Start-Up • Parts • Maintenance Figure 34 GCM (control module) harness plug receptacle and indicator light locations.
GOLD GV Water boiler series 3 — manual XIf Troubleshooting — common problems Symptom Common Causes Possible Corrections Rapid cycling — boiler turns on and off frequently Thermostat installed where drafts or heat affect reading Locate thermostat on inner wall away from heat sources or cool drafts. Heat anticipator in thermostat adjusted incorrectly Adjust thermostat per manufacturer’s instructions. Incorrect limit setting Set limit according to system needs. Maximum setting is 220˚F.
• Installation • Start-Up • Parts • Maintenance Symptom Common Causes Possible Corrections Popping or percolating noise heard in boiler Mineral deposits in sections due to constant use of makeup water Call qualified service technician to de-lime boiler, if necessary. In some cases, deposits will be too heavy to remove with de-liming procedures. Have qualified service technician repair leaks to eliminate need for constant makeup water.
GOLD GV Water boiler series 3 — manual XIg Troubleshooting — GCM lights CHART 1 — Troubleshooting POWER light status 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. Is POWER light off? No • Make sure service switch or circuit breaker is on or fuses are good. • Remove 120 VAC IN plug (Figure 34, Item 1) on control module.
• Installation • Start-Up • Parts • Maintenance CHART 2 — TSTAT CIRC & POWER lights flashing 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. Is return water temperature sensor clamped securely to the return pipe in the boiler? Yes No • Attach sensor to pipe with clamp provided. • If problem persists, replace return water temperature sensor. • Retest.
GOLD GV Water boiler series 3 — manual XIg Troubleshooting — GCM lights (continued) CHART 3 — LIMIT & POWER lights flashing 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. • This is a lockout condition.
• Installation • Start-Up • Parts • Maintenance 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. • Reset boiler control by turning off power at service switch or turning down thermostat for at least 45 seconds. • Thermostat should call for heat and appropriate zone valves open.
GOLD GV Water boiler series 3 — manual XIg Troubleshooting — GCM lights (continued) CHART 5 — FLAME & 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. Are manual main shutoff valve and gas valve turned on? No • Open manual gas valve. • Restart boiler, following Lighting instructions for gas valve installed on boiler (Figure 25 or 26).
• Installation • Start-Up • Parts • Maintenance CHART 6 — TSTAT CIRC light flashing and 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 substantial property damage. • This is not a lockout mode. The control module is signaling that the return water temperature sensor is detecting a temperature less than 40 ˚F.
GOLD GV Water boiler series 3 — manual XIg Troubleshooting — GCM lights (continued) CHART 7 — LIMIT light flashing and 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 substantial property damage. • This is not a lockout mode.
• Installation • Start-Up • Parts • Maintenance 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 substantial property damage. • Has it been at least 5 minutes since setting thermostat to call for heat? If not, wait 5 minutes.
GOLD GV Water boiler series 3 — manual XIIa Replacement parts — overview ❏ Accessory bag assembly (shipped with boiler) ❏ Section assembly (boiler sections, tie rods, base rail legs, blower support bracket, block temperature switch) ❏ Jacket assembly (jacket parts) ❏ Blower assembly (blower, motor, air inlet hose and fittings, condensate trap parts, igniter, gas valve, gas/air orifice and manifold, burner and gasket) ❏ Trim assembly (circulators, piping components, limit control, P/T gauge, relief valve,
• Installation • Start-Up • Parts • Maintenance XIIb Replacement parts — accessory bag Table 5 The parts below are shipped with the boiler in the accessory bag. Item Description number 1 Water trim bag assembly #2 Weil-McLain part number Quantity Remarks 542-200-309 1 Nipple, BK 1 x 3.
GOLD GV Water boiler series 3 — manual XIIc Table 6 Replacement parts — section assembly Section assembly Item Description number 1 Weil-McLain part number Block assembly, includes: Front section, intermediate section, back section, square cut seals — 2", silicone sealant, tie rods, tie rod nuts, tie rod washers, water tubing male adapters — 1" NPT, water tubing, pump to return, blower flange gasket, igniter, igniter gasket, screws, lock washers, studs, nuts 3 322-200-280 4 322-200-281 5 322-200
• Installation • Start-Up • Parts • Maintenance Figure 35 Section assembly 85041 Part number 550-141-850/0699 85
GOLD GV Water boiler series 3 — manual XIId Table 7 Item number 1 86 Replacement parts — jacket assembly Jacket assembly Description Jacket panel, top 2 Jacket panel, front 3 Jacket panel , left side 4 Jacket access panel 5 Jacket panel, right side Model Weil-McLain part number 3&4 422-200-146 5&6 422-200-150 All 422-200-140 3&4 422-200-220 5&6 422-200-222 All 422-200-230 3&4 422-200-224 5&6 422-200-226 6 Jacket panel, rear All 422-200-135 7 Top rail brace All 422-2
• Installation • Start-Up • Parts • Maintenance Figure 36 Jacket assembly 85042 Part number 550-141-850/0699 87
GOLD GV Water boiler series 3 — manual XIIe Table 8 Replacement parts — Blower assembly Blower assembly Item number Description 1 Burner replacement kit, includes: Burner cone and ring assembly, blower flange gasket, igniter, igniter screws, igniter washers, igniter gasket 2 3 4 Blower flange gasket Air pressure switch (0 to 5,500 feet elevation) Blower motor replacement kit, includes: Blower motor, motor mount grommets, screws, lock nuts, 9" Allen wrench Blower housing assembly replacement kit, in
• Installation • Start-Up • Parts • Maintenance Figure 37 Blower assembly Vent starter tee — not included 85043 Part number 550-141-850/0699 89
GOLD GV Water boiler series 3 — manual XIIf Table 9 Replacement parts — trim assembly Trim assembly Item Description number 90 Weil-McLain part number 1 Circulator flange, 1" NPT 563-910-026 2 Circulator gasket, Taco 110-339 3 System circulator, Taco 007F 590-317-543 511-405-113 4 Bypass circulator, Taco 007F 511-405-113 5 Wiring harness, dual circulators to control module 591-391-824 6 Nipple, NPT — 1" x close 561-326-500 7 Ell, 1" 563-115-300 8 Nipple, NPT — 1" x 4 ½" 561-326-
• Installation • Start-Up • Parts • Maintenance Trim assembly SYST EM Figure 38 85048 Part number 550-141-850/0699 91
GOLD GV Water boiler series 3 — manual XIIg Table 10 Replacement parts — interior panel Interior panel Item Description number 92 Weil-McLain part number 1 Interior panel with controls 542-200-302 2 Control module assembly, includes control module and screws 542-200-235 3 Transformer 511-842-370 4 Air pressure switch 511-624-520 5 Wiring harness, control module to junction box (not shown) 591-391-821 6 Wiring harness, control module to hot surface ignitor (not shown) 591-391-819 7
• Installation • Start-Up • Parts • Maintenance Figure 39 Interior panel 85046 Part number 550-141-850/0699 93
GOLD GV Water boiler series 3 — manual XIII Figure 40 Dimensions and ratings Dimension drawing (see dimension table on opposite page) L 85049 Item number 1 2 3 4 5 6 7 8 9 10 11 12 13 94 Description 1" NPT Supply 1" NPT Return Combination pressure-temperature gauge, 2 ½" short shank ¾" NPT Relief valve outlet Plug dome, 2" black Junction box Inlet air fitting 3" Diameter flue outlet ½" Condensate drain ½" NPT Gas supply connection (provided by others) Drip leg (provided by others) Union (provided by
• Installation • Start-Up • Parts • Maintenance Table 11 Boiler model Boiler dimensional data (see Figure 40) Supply Return Length L Gas connection size (Note 1) Crate dimensions (outside measurement, inches) Approx. shipping weight (in. NPT) (in. NPT) (inches) (in.
GOLD GV W ater boiler — Series 3 Water Weil-McLain 500 Blaine Street Michigan City, IN 46360-2388 http://www.weil-mclain.
