Weil-McLain Gold GV 3 Series Owner's manual

Part number 550-110-266/0601
Hazard definitions
The following defined terms are used throughout these Instructions 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.
Indicates presence of hazards that will or can cause minor personal injury
or property damage.
Indicates special instructions on installation, operation or maintenance that
are important but not related to personal injury or property damage.
To the installer:
This Venting Supplement must only be used by a qualified installer/service
technician. Read these Instructions completely before beginning the
installation.Failure to follow all instructions can cause severe personal injury,
death or substantial property damage.
To install a new vent system follow instructions in:
• This Venting Supplement.
• GV Boilers Vent/Air Intake Termination Assembly Instructions, if
using Weil-McLain Vent/Air Intake Termination Kit. — OR —
• GV Water Boiler Series 3 & 4 Direct Vent Through-Roof or Through-
Unused-Chimney Venting Supplement, if using Weil-McLain
Through-Roof or Through-Unused-Chimney Termination Kit.
• Z-Vent II manufacturer’s instructions supplied with vent material.
For installations above 5,500 feet use only direct vent (ducted combustion
air) when sidewall venting. All of the vertical (through-roof or through-
unused-chimney) methods in this Venting Supplement are acceptable and
can result in severe personal injury, death or substantial property damage
if ignored.
Z-Vent II
Venting Supplement
Special gas vent system vent and combustion air supplement
Z-Flex®, Inc. Z-Vent II AL29-4C®Stainless Steel Special Gas Vent System may be used in new
installations of GV-3 through GV-6 boilers.
GOLD
Water Boiler — Series 3 & 4
GV

Part number 550-110-266/0601
2
GOLD GV Series 3 & 4 — Z-Vent II Venting Supplement
Combustion air supply
Table 1 Corrosive contaminants
Special note
Refer to GV Boiler Manual for sizing free area of combustion/ventilation air openings.
All boilers experience some condensation in section assembly during start-up. Unlike most conventional boilers,
condensation is minimized in the GV Boiler by a built-in mixing system, maintaining boiler return water
temperature above 130 0F, during steady state operation.
Flue gas condensate is slightly acidic. In most cases pH level is not harmful to vents or drains. When combustion
air is contaminated by vapors from products and areas, listed in Table 1 below, condensate acidic levels increase.
Higher acidic levels attack many materials, including stainless steel commonly used in high efficiency systems.
You may choose to use outside combustion air for any of the following reasons:
• Installation is in an area containing contaminants listed in Table 1 below, which will induce acidic
contamination.
• You want to reduce infiltration into your home through openings around windows and doors.
Products to avoid Areas likely to have contaminants
Spray cans containing chloro/fluorocarbons Dry cleaning/laundry areas and establishments
Permanent wave solutions Swimming pools
Chlorinated waxes/cleaners Metal fabrication plants
Chlorine-based swimming pool chemicals Beauty shops
Calcium chloride used for thawing Refrigeration repair shops
Sodium chloride used for water softening Photo processing plants
Refrigerant leaks Auto body shops
Paint or varnish removers Plastic manufacturing plants
Hydrochloric acid/muriatic acid Furniture refinishing areas and establishments
Cements and glues New building construction
Antistatic fabric softeners used in clothes
dryers Remodeling areas
Chlorine-type bleaches, detergents, and clean-
ing solvents found in household laundry rooms Garages with workshops
Adhesives used to fasten building products and
other similar products
To prevent the potential of severe personal injury or death, check for areas and products listed
above before installing boiler. If found:
• remove products permanently — OR —
• provide outside combustion air

Part number 550-110-266/0601 3
GOLD GV Series 3 & 4 — Z-Vent II Venting Supplement
Vent termination
Venting method definitions
Direct vent — Uses outside combustion air with
combustion air connector piping sealed at all joints and
seams. Also known as “sealed combustion”.
Non-Direct vent — Uses inside combustion air with no
combustion air connector piping.
Properly locate vent termination
Follow instructions on this page
when determining vent location to
avoid possibility of severe personal
injury, death or substantial property
damage.
1. When using direct vent method — Refer to separate
instructions packed with Weil-McLain direct vent
termination kit and vent pipe manufacturer's
instructions for additional locations.
2. For location of non-direct vent vertical termination,
see vent pipe manufacturer's instructions.
3. Gases will form white plume in winter. Plume could
obstruct window view.
4. Prevailing winds could cause freezing of condensate
and water/ice buildup on building, plants or roof.
5. Locate or guard vent to prevent accidental contact
by people or pets.
6. Do not terminate vent in window well, stairwell,
alcove, courtyard, or other recessed areas.
7. Non-Direct vent installations only — Vent must
terminate more than 4 feet below or to side of all doors or windows.
8. Vent must terminate more than 1 foot above grade or anticipated snow
line. In addition, vent termination must be at least 7 feet above public
walkway and 3 feet above any forced air intake within 10 feet. Stay well
away from trees, shrubs, and decorative items. Site conditions may
dictate greater clearances. See Figure 1.
9. Vent must terminate at least 4 feet horizontally, and in no case above
or below, unless a 4 foot horizontal distance is maintained,from electric
meters, gas meters, regulators, relief valves, and other equipment.
10. Locate or guard vent to prevent condensate from damaging exterior
finishes.
11. Do not extend exposed vent pipe outside of building. Condensate could
freeze and block vent pipe.
12. Vent must terminate at least 6 feet away from adjacent walls.
13. Do not terminate vent closer than 5 feet below roof overhang.
14. Do not terminate vent above any door or window. Condensate can
freeze, causing ice formations.
15. Do not use existing chimney as raceway if another appliance or fireplace
is vented into or through chimney.
16. Do not connect:
• Any other appliance to vent pipe.
• Multiple boilers to a common vent pipe.
17. Do not wrap or insulate vent pipe and fittings.
18. Canadian installations — See B149.1 or B149.2 Installation Code.
19. A gas vent extending through an exterior wall shall not
terminate adjacent to the wall or below building
extensions such as eaves, parapets, balconies or decks.
Failure to comply could result in severe personal injury,
death or substantial property damage.
Figure 1 Vent termination locations
26607
Forced
air intake
Public Walkway
3 feet
If within 10 feet
7 feet
26608
Snow
1 foot
1 ft 1 ft
1 ft

Part number 550-110-266/0601
4
GOLD GV Series 3 & 4 — Z-Vent II Venting Supplement
Installation
Pre-installation planning
1. Follow national, state, local or provincial codes or
regulations when venting GV boiler.
2. Choose vent method from those shown on page 5.
3. Select vent run components from Table 2. Table 3
states maximum vent run lengths and number of
elbows. Do not exceed data in Table 3. See Figure 2
for slightly reduced boiler output.
4. If installing with direct vent method, use same maximum run length
and number of elbows from step 2.Vent and combustion air connector
piping configurations must match. Use suitable 3" material for
combustion air connector piping, such as:
• Dryer vent
• Galvanized steel
• PVC (3" I.D.)
5. Refer to vent termination WARNING, item 19 on page 3.
Table 3
Vent and combustion air connector piping
lengths and number of elbows
GV-6
GV-5
GV-4
GV-3
020 40 60 80 100
Total equivalent length (feet) of vent
(from boiler to vent termination)
% Output
95
96
98
97
99
100
26700
Figure 2 Boiler output
Maximum vent
length (feet) Total number of elbows
0 2 3 4 5 6 7 8
GV-3 thru GV-5 100 80 70 60 50 40 30 20
GV-6 80 60 50 40 30 20 10 --
Table 2 Parts list
Description Z-Flex®, Inc.
Part Number (Note 1)
GV starter tee SVEVST03
GV termination coupling SVSTPX03
45oelbow SVEEWC0345
90oelbow SVEEWC0390
6" pipe SVEPWC03.5
1' pipe SVEPWC0301
2' pipe SVEPWC0302
3' pipe SVEPWC0303
4' pipe SVEPWC0304
5' pipe SVEPWC0305
Locking band SVSLBX03
Weil-McLain Vent/Air Intake Termination Kit 382-200-430 (Note 2)
Weil-McLain Through-Roof or Through-Unused-Chimney Termination Kit 382-200-435 (Note 2)
Notes
1. Z-Flex
®
, Inc. part number. Parts available through Z-Flex
®
, Inc.
2. Weil-McLain part number. Parts available through Weil-McLain distributor.

Part number 550-110-266/0601 5
GOLD GV Series 3 & 4 — Z-Vent II Venting Supplement
Figure 3 GV direct vent through sidewall
(using Weil-McLain Vent/Air Intake Termination Kit)
Installation continued
For altitudes more than 5,500 feet above sea level — Do not use non-direct vent through sidewall methods as
shown in Figures 4 and 6 below. Can cause severe personal injury, death or substantial property damage if ignored.
Figure 4 GV non-direct vent through sidewall (using Weil-
McLain Vent/Air Intake Termination Kit) (See WARNING above.)
Figure 5 GV direct vent (using Weil-McLain
Through-Roof or Through-Unused Chimney
Termination Kit)
Figure 6 GV non-direct vent
through sidewall (using termina-
tion coupling) (See WARNING
above.)
Figure 7 GV non-direct vent
through roof (See WARNING
above.)
26601
Air pipe
Vent pipe
Z-Vent II
vent starter tee
Slope vent pipe downward, toward
boiler, minimum ¼” per foot.
Slope
26603
Slope vent
pipe
downward,
toward
boiler,
minimum
¼” per foot.
Z-Vent II
vent starter tee
26602
Z-Vent II
vent starter tee
Slope vent pipe
downward, toward
boiler, minimum ¼”
per foot.
Slope
26604
Slope vent pipe
downward, toward
boiler, minimum
¼” per foot.
Z-Vent II
vent starter tee
Select vent method
26605b
Z-Vent II
vent starter tee

Part number 550-110-266/0601
6
GOLD GV Series 3 & 4 — Z-Vent II Venting Supplement
Installation — assembly
Connect vent starter tee to boiler
Follow the instructions in the GV Boiler Manual to connect the vent starter tee to the boiler.
Construct vent and optional combustion air run
Follow vent pipe manufacturer's instructions for sealing the vent. Vent and
combustion air connector piping must be sealed gas-tight to prevent
possibility of flue gas spillage and carbon monoxide emissions, resulting in
severe personal injury or death.
1. Follow Z-Vent II manufacturer's instructions to construct vent run and for methods of
supporting vent runs.
• Clean joints before sealing. See vent pipe manufacturer's instructions to clean joints.
• Use their specified sealant (maximum 250 °F flue temperature). Do not use screws.
• Do not mix types or manufacturers of vent materials.
• Maintain minimum one-inch clearance from combustible materials to vent pipe; 0"
clearance for noncombustible materials.
• Install vent pipe with seams on top of vent runs.
• If needed, male end of vent pipe may be cut to provide correct length. See vent pipe
manufacturer's instructions for use.
2. If installing with direct vent through sidewall method, use instructions provided with
Weil-McLain Vent/Air Intake Termination Kit. See Figure 3 on page 5.
Connect vent run to termination
Venting through sidewall
1. If using Weil-McLain Vent/Air Intake Termination Kit, see instructions provided in that
kit. Applies to direct (Figure 3, page 5) or non-direct vent (Figure 4, page 5) method.
2. If using non-direct method with termination coupling only, see Figures 8 and 9.
• If passing through noncombustible wall, provide hole diameter large enough to insert
the slip connector through. Sleeve and spacers are not required.
3. Maintain minimum one-inch clearance from combustible materials to vent pipe; 0"
clearance for noncombustible materials.
4. Refer to vent termination WARNING, item 19 on page 3.
Venting through existing chimney or roof
1. Direct vent method — follow instructions supplied in Weil-McLain Through-Roof or
Through-Unused-Chimney Termination Kit to assemble termination.
2. Non-Direct vent method (only through the roof, not through chimney):
• Vent pipe must extend through roof flashing, jacket or thimble. See Figure 10.
• Vent may pass through floor, inside wall or concealed space when installed according
to vent pipe manufacturer's instructions.
2. Maintain minimum one-inch clearance from combustible materials to vent pipe.

Part number 550-110-266/0601 7
GOLD GV Series 3 & 4 — Z-Vent II Venting Supplement
Installation — assembly continued
Figure 8 Sidewall termination installation (non-direct venting)
Figure 9 Non-direct vent through sidewall
(using termination coupling) Follow Z-Vent II
manufacturer’s instructions for proper installation of
vent runs, including slope and support.
Figure 10 Non-direct vent through roof
Follow Z-Vent II manufacturer’s instructions for proper
installation of vent runs, including slope and support.
26604b
Z-Vent II
vent starter tee
26605b
Z-Vent II
vent starter tee
26609
¼" to ¾" between stop
on termination and
metal plate
4" galvanized sleeve
(through 4 " hole for
wall)
¹⁄₈
combustible
Spacers (2)
(to support and
center vent in
sleeve)
Spacers (2)
(to support and
center vent in
sleeve)
Termination coupling
Sealant
Sealant
Pipe section
Pipe section
Metal plate
Metal plate

8
GOLD GV Series 3 & 4 — Z-Vent II Venting Supplement
Part number 550-110-266/0601
Installation — assembly continued
Finish the vent installation
Installing condensate tubing
1. See Figure 11 to install condensate tubing (provided
by others). Use condensate pump if floor drain is
higher than condensate drain on boiler.
If required:
• use a low-profile pump — OR —
• set boiler on foundation (see GV Boiler
Manual) to allow gravity flow to discharge.
2. Size pump in gal/hr (boiler model):
• 0.78 (GV-3)
• 1.17 (GV-4)
• 1.56 (GV-5)
• 1.95 (GV-6)
Refer to pump manufacturer's instructions. Drain
to a non-freezing area.
Figure 11 Installation of condensate tubing
26606
Z-Vent II
vent starter tee
5/8" O.D. tubing,
provided by
others
Vent
If vent pipe or combustion air pipe must be reassembled
When vent pipe or combustion air pipe is disconnected for any reason, it must be reassembled and resealed
according to this Venting Supplement, the direct vent termination kit instructions and the vent pipe manufacturer's
instructions.
Sealant recommended by vent pipe manufacturer must be used as indicated in their instructions.
Vent and combustion air connector piping must be sealed gas-tight to prevent possibility of
flue gas spillage and carbon monoxide emissions, resulting in severe personal injury or death.