Weil-McLain Gold GV 3 Series User manual

Part Number 550-110-271/0699
Special gas vent system vent and combustionSpecial gas vent system vent and combustion
Special gas vent system vent and combustionSpecial gas vent system vent and combustion
Special gas vent system vent and combustion
air supplement for 4" diameter ventingair supplement for 4" diameter venting
air supplement for 4" diameter ventingair supplement for 4" diameter venting
air supplement for 4" diameter venting
Venting Supplement
Saf-Saf-
Saf-Saf-
Saf-T VT V
T VT V
T Ventent
entent
ent®®
®®
®—4” venting
Heat-Fab, Inc. Saf-T Vent®AL29-4C®Stainless
Steel Special Gas Vent System may be used in
new installations of GV-3 through GV-6 boilers.
To the installer: ThisVentingSupplementmustonlybeusedbyaqualifiedinstaller/service
technician. Read these instructions completely before beginning the
installation.Failure to follow these instructions in proper order can cause
severe personal injury,death or substantial property damage.
To install a new vent system follow instructions in:
•ThisVentingSupplement.
•GV Boilers Vent/Air Intake Termination Assembly Instructions, if
using Weil-McLain Vent/Air Intake Termination Kit.
•Saf-T Vent®manufacturer’s instructions supplied with vent material.
Forinstallationsabove 5,500feetuse onlydirectvent(ductedcombustion
air) when sidewall venting. All of the vertical (through-roof or through-
unused-chimney)methodsinthisVentingSupplementareacceptable.Can
result in severe personal injury, death or substantial property damage if
ignored.
4" Diameter vent lengths are determined using standard 3" diameter GV
starters and 24" or less of 3" diameter vent termination length.
GOLDGOLD
GOLDGOLD
GOLD GVGV
GVGV
GV
WW
WW
Water boiler — Series 3ater boiler — Series 3
ater boiler — Series 3ater boiler — Series 3
ater boiler — Series 3
The following terms are used throughout this Venting Supplement 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
orsubstantial property damage.
Indicates presence of hazards that can cause severe personal injury,death
orsubstantial property damage.
Indicatespresence of hazardsthatwillor cancause minor personal injury
orpropertydamage.
Indicates special instructions on installation, operation or maintenance
that are important but not related to personal injury or property damage.
Hazard definitions

Part Number 550-110-271/0699
2
GOLD GV Water boiler — Series 3
Combustion air supply
RefertoGV Series 3 Boiler Manual forsizingfreeareaof combustion/ventilationairopenings.
All boilers experience some condensation in section assembly during start-up. Unlike most
conventionalboilers,condensationisminimizedintheGV Series 3 Boiler byabuilt-inmixing
system,maintainingboilerreturnwatertemperatureabove1300F,duringsteadystateoperation.
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
anddoors.
Special note
Topreventpotentialofseverepersonalinjuryordeath,checkforareasand
products listed above before installing boiler. If found:
•remove products permanently — OR —
•provide outside combustion air
Table 1 Corrosive contaminants
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

Part Number 550-110-271/0699 3
Saf-T Vent®Venting Supplement for 4" diameter venting
Vent termination
Venting method definitions
Figure 1 Vent termination locations
27107
Forced
air intake
Public Walkway
3 feet
If within 10 feet
7 feet
27108
Snow
1 foot
1 ft 1 ft
1 ft
1. When using direct vent method — Refer to separate
instructionspackedwithWeil-McLaindirectventtermination
kit and vent pipe manufacturer's instructions for additional
locations.
2. Forlocationof non-directventverticaltermination,seevent
pipemanufacturer's instructions.
3. Gaseswillformwhiteplumeinwinter.Plumecouldobstruct
windowview.
4. Prevailing winds could cause freezing of condensate and
water/ice buildup on building, plants or roof.
5. Locateorguardventtoprevent accidentalcontactbypeople
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
morethan4feetbelowortosideofalldoorsorwindows.See
Figure 1.
8. Vent must terminate more than 1 foot above grade or
Properly locate vent termination
anticipatedsnowline.Inaddition,ventterminationmustbe
atleast7feetabovepublicwalkwayand3feetaboveanyforced
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,fromelectricmeters,gasmeters,regulators,relief
valves, and other equipment.
10. Locate or guard vent to prevent condensate from damaging
exteriorfinishes.
11. Do not extend exposed vent pipe outside of building.
Condensate could freeze and block vent pipe.
12. Vent mustterminateat least6feet awayfrom adjacentwalls.
13. Donotterminateventcloserthan5feetbelowroofoverhang.
14. Donotterminateventaboveanydoororwindow.Condensate
can freeze,causing ice formations.
15. Do notuseexistingchimneyas raceway if anotherappliance
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 CAN/CGA B149.1 or B149.2
InstallationCode.
19. A gas vent extending through an exterior
wall shall not terminate adjacent to the
wallorbelow buildingextensionssuch as
eaves,parapets,balconiesordecks.Failure
to comply could result in severe personal
injury, death or substantial property
damage.
Follow instructions on this page when
determiningventlocationtoavoidpossibility
ofseverepersonalinjury,deathorsubstantial
property damage.
Direct vent — Uses outside combustion air with combustion
airconnectorpipingsealedatalljointsandseams.Alsoknownas
“sealedcombustion”.
Non-Direct vent — Uses inside combustion air with no
combustion air connector piping.

Part Number 550-110-271/0699
4
GOLD GV Water boiler — Series 3
Installation
Pre-installation planning
1. Follow national, state,local or provincial codes or
regulationswhenventing GV boiler.
2. Chooseventmethodfromthoseshownon page5.
3. Selectventrun 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
maximumrun lengthand number of elbowsfrom
Description Weil-McLain
Part Number Heat-Fab, Inc. Part Number 4" dia. (Note 2 & 3)
GV starter tee 699-999-025 73WMSTXL
GV termination coupling 699-999-001 73WMTERM
45
o
elbow
Available
through
local
supply
house.
7411GC
90
o
elbow 7414GCTR
6" pipe 7401GC
12" pipe 7402GC
18" pipe 7404GC
18" slip connector (Note 1) 7424GC
24" pipe 7405GC
37 ½" pipe 7407GC
49 ½" pipe 7408GC
Horizontal support 7423GC
3 Inch diameter to 4 inch diameter transition 7374GC
4 Inch diameter to 3 inch diameter transition 7473RDCR
Weil-McLain Vent/Air Intake Termination Kit 382-200-430 --
Notes
1. Use to adjust for non-standard pipe lengths and before termination coupling to terminate run
2. The GV boiler vent connection is always 3 inch diameter, requiring a 3" to 4" vent adapter when 4" vent is
used.
3. Through-Roof or Unused-Chimney Termination Kit not certified with 4" diameter vent.
Table 2
Parts list
step 2.Vent and combustion air connector piping
configurationsmustmatch.Usesuitable3"material
for combustion air connector piping,such as:
•Dryer vent
•Galvanizedsteel
•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
Total number of elbows
0 2 3 4 5 6 7 8
Maximum vent
length (feet) 150 130 120 110 100 90 80 70
Note: 4" Diameter vent lengths are determined using
standard 3" diameter GV starters and 24" or less of 3"
diameter vent termination.
Figure 2 Boiler output
GV-6
GV-5
GV-4
GV-3
0 20406080 100 150
Total equivalent length (feet) of vent
(from boiler to vent termination)
% Output
95
96
98
97
99
100
27100

Part Number 550-110-271/0699 5
Saf-T Vent®Venting Supplement for 4" diameter venting
27101
Saf-T Vent
vent starter tee
®
Slope vent pipe downward, toward
boiler, minimum ¼” per foot.
Slope down
Air
Vent
Install 4-to-3 reducer
with flat side
to increase
clearance between flue
pipe and air pipe.
toward air
pipe
3-to-4
increaser
vertical
Figure 3 GV direct vent through sidewall
(using Weil-McLain Vent/Air Intake
Termination Kit)
Figure 5 GV non-direct vent through sidewall
(using termination coupling)
(See WARNING above.)
27104
Slope vent pipe downward, toward boiler,
minimum ¼” per foot.
Saf-T Vent
vent starter tee
®
3-to-4
increaser
vertical
4-to-3
reducer
If installing 4-to-3 reducer in
horizontal piping, always
mount with flat side to
allow drainage of condensate
back to the boiler.
DOWN
27102
Saf-T Vent
vent starter tee
®
Slope vent pipe downward, toward
boiler, minimum ¼” per foot.
Slope down
Vent
3-to-4
increaser
vertical
Figure 4 GV non-direct vent through sidewall
(using Weil-McLain Vent/Air Intake
Termination Kit) (See WARNING above.)
27105
Saf-T Vent
vent starter tee
®
Slope vent pipe downward, toward
boiler, minimum ¼” per foot.
3-to-4
increaser
vertical
Figure 6 GV non-direct vent through roof
Select vent method:
For altitudes more than 5,500 feet above sea level — Do not use non-direct vent through sidewall methods as
showninFigures 4 and5below.Cancauseseverepersonalinjury,deathorsubstantialpropertydamageif ignored.

Part Number 550-110-271/0699
6
GOLD GV Water boiler — Series 3
Installation — assembly
Construct vent and
optional
combustion air run
Followventpipemanufacturer'sinstructionsforsealingthevent.Ventand
combustion air connector piping must be sealed gas-tight to prevent
possibilityoffluegasspillageandcarbonmonoxideemissions,resultingin
severe personal injury or death.
1. FollowSaf-T Vent®manufacturer'sinstructionstoconstructvent runand formethodsof
supporting vent runs.
•Clean joints before sealing. See vent pipe manufacturer's instructions to clean joints.
•Use their specified sealant (maximum 250 0F 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 fornoncombustiblematerials.
•Installventpipe withseams ontopof vent runs.RefertoFigures 3 through6 on page
5 when installing increasersor reducers.
•If needed, use slip connector to adjust for nonstandard pipe length. See vent pipe
manufacturer'sinstructions foruse.
2. Ifinstallingwithdirectventthroughsidewallmethod,useinstructionsprovidedwithWeil-
McLainVent/Air Intake Termination Kit.See Figure 3, page 5.
Connect vent starter
tee to boiler Follow the instructions in the GV Series 3 Boiler Manual section IIII
IIII
IIbb
bb
bto connect the vent
starter tee to the boiler.
1. Non-Direct vent method (only through the roof, not through chimney):
•Vent pipe must extend through roof flashing, jacket or thimble.See Figure 9.
•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.
Venting through roof
Venting through sidewall
1. If using Weil-McLainVent/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 7 and 8.
•Do not seal slip connector to inside oroutside plate.
•If passingthrough noncombustiblewall,providehole diameterlarge enoughtoinsert
the slip connector through. Sleeve and spacers are not required.
3. Maintain minimum one-inch clearance from combustible materials to vent pipe; 0"
clearance fornoncombustiblematerials.
4. Refer to vent termination WARNING,item 19 on page 3.
Connect vent run to
termination

Part Number 550-110-271/0699 7
Saf-T Vent®Venting Supplement for 4" diameter venting
27104b
Saf-T Vent
vent starter tee
®
3-to-4
increaser
vertical
4-to-3
reducer
If installing 4-to-3 reducer in
horizontal piping, always
mount with flat side to
allow drainage of condensate
back to the boiler.
DOWN
Figure 7 Sidewall termination installation (non-direct venting)
27109
Sealant
Sealant
4" Pipe section
4" to 3" Transition
Band clamp
Metal plate
Metal plate
4" Galvanized sleeve
(within 4-1/8" hole for
combustible wall)
1/8" Slip connector, 3"
Spacer to support sleeve on vent
¼" to ¾" between stop on
termination and metal plate
27105b
Saf-T Vent
vent starter tee
®
3-to-4
increaser
vertical
Figure 8 Non-direct vent through sidewall
(using termination coupling)
Follow Saf-T Vent
®
manufacturer’s
instructions for proper installation of vent
runs, including slope and support.
Figure 9 Non-Direct vent through roof
Follow Saf-T Vent
®
manufacturer’s
instructions for proper installation of vent
runs, including slope and support.

Part Number 550-110-271/0699
8
GOLD GV Water boiler — Series 3
Weil-McLain
500 Blaine Street
Michigan City, IN 46360-2388
http://www.weil-mclain.com
Installation — assembly continued
Finish the vent
installation Figure 10
Installation of condensate tubing
27106
Saf-T Vent
vent starter tee
®
5/8" O.D. tubing,
provided by
others
Vent
Sealantrecommendedbyventpipemanufacturermustbeusedasindicated
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.
1. See Figure 10 to install condensate tubing
(providedbyothers).Usecondensatepump
if floor drain is higher than condensate
drain on boiler.
If required:
• use a low-profile pump — OR —
• setboileronfoundation(seeGV Series
3 Boiler Manual)toallowgravityflow
to pump.
2. Size pump in gal/hr (boiler model):
• 0.78(GV-3)
• 1.17(GV-4)
• 1.56(GV-5)
• 1.95(GV-6)
Refertopumpmanufacturer'sinstructions.
Drain to a non-freezing area.
Installing condensate tubing
If vent pipe or combustion air pipe must be reassembled
Whenventpipeorcombustionairpipeisdisconnectedforanyreason,itmustbereassembled
andresealedaccordingtothisVentingSupplement,thedirectventterminationkitinstructions
and the vent pipe manufacturer's instructions.