Weil-McLain Gold GV 3 Series User manual

Part number 550-141-923/0710
Water Boiler — Series 3 & 4
GOLD GV
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.
• Vent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.
Venting Supplement
for 3” venting
Special gas vent system vent and combustion air
supplement for 3” diameter venting.
Thefollowingmanufacturers’AL29-4C®StainlessSteelSpecialGasVentSystemmaybeused
innewinstallationsofGV-3throughGV-6boilers:
• Heat-Fab,Inc.Saf-T Vent®
• Metal-Fab,Inc.CORR/GUARD
• Z-Flex®,Inc.Z-Vent II
• ProTechSystemsFasNSeal™

Part number 550-141-923/0710
2
GOLD GV Series 3 & 4 — Venting Supplement for 3.00” venting
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efciency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inltrationintoyourhomethroughopeningsaroundwindowsanddoors.
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
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 550-141-923/0710 3
GOLD GV Series 3 & 4 — Venting Supplement for 3.00” venting
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. Whenusingdirect vent method—Refertoseparate
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. Vent may pass through an unused chimney or vent as a raceway if
allowedbyventmanufacturerandinstalledperventmanufacturer’s
instructions.
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ttings.
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 Non-Direct Vent termination locations
26507
Forced
air intake
Public Walkway
3 feet
If within 10 feet
7 feet

Part number 550-141-923/0710
4
GOLD GV Series 3 & 4 — Venting Supplement for 3.00” venting
Figure 2 Boiler output
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 theCGi, CGs
& GV Vent Component Supplement. Table 2
statesmaximumventrunlengthsandnumberof
elbows.DonotexceeddatainTable2.SeeFigure
2forslightlyreducedboileroutput.
4. Thefollowing items are available throughWeil-
McLain:
• Weil-McLain Vent/Air Intake Termination
Kit(partnumber382-200-430).
• Weil-McLain Through-Roof or Through-
Unused-Chimney Termination Kit (part
number382-200-435).
5. If installing with direct vent method, use same
maximumrun length and number of elbows
fromstep2.Ventandcombustionairconnector
pipingcongurationsmustmatch.Usesuitable3”
material for combustion air connector piping, such
as:
• Dryervent
• Galvanizedsteel
• PVC(3”I.D.)
6. RefertoventterminationWARNING,item19on
page3.
Table 2 Vent and combustion air connector piping lengths and
number of elbows
Figure 3 GV direct vent through sidewall
(using Weil-McLain Vent/Air Intake Termination Kit)
Figure 4 GV non-direct vent through sidewall (using Weil-
McLain Vent/Air Intake Termination Kit) (See WARNING above.)
 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.Cancauseseverepersonalinjury,deathorsubstantialpropertydamageifignored.
Select vent method
GV-6
GV-5
GV-4
GV-3
0 20 40 6080 100
Total equivalent length (feet) of vent
(from boiler to vent termination)
% Output
95
96
98
97
99
100
26500

Part number 550-141-923/0710 5
GOLD GV Series 3 & 4 — Venting Supplement for 3.00” venting
Installation continued
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)
Select vent method continued
Figure 7 GV non-direct vent
through roof (See WARNING
above)
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vent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specied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fornoncombustiblematerials.
• Installvent pipewith seamson top of vent
runs.
• Ifneeded:
a. Saf-T Vent® and CORR/GUARD—use
slip connector to adjust for nonstandard
pipe lengths.
b. Z-Vent II and FasNSeal™—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page4.

Part number 550-141-923/0710
6
GOLD GV Series 3 & 4 — Venting Supplement for 3.00” venting
Installation — assembly
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4)ornon-direct
vent(Figure4,page4)method.
2. Ifusingnon-directmethodwithterminationcouplingonly,seeFigures
8 and 10.
• Donotsealslipconnectortoinsideoroutsideplate.
• 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(throughtheroof):
• Ventpipemustextendthroughroofashing,jacketorthimble.
SeeFigure9.
• Ventmaypassthroughoor,insidewallorconcealedspacewhen
installedaccordingtoventpipemanufacturer’sinstructions.
3. Maintainminimumone-inchclearancefromcombustiblematerials
to vent pipe.
Figure 8 Non-direct vent
through sidewall (using termina-
tion coupling)
Follow vent manufacturer’s instruc-
tions for proper installation of vent
runs, including slope and support.
Figure 9 Non-direct vent
through roof
Follow vent manufacturer’s
instructions for proper installation
of vent runs, including slope and
support.
Install combustion air piping
1. Seal all combustion air piping joints and seams,
using sealant as below:
a. Dryer vent—Apieceof3”galvanizedisre-
quired at each end to adapt. Seal all pipe joints
and seams between pipe and dryer vent with
silicon sealant.
b. Galvanized pipe—Sealalljointsandseams
using silicone sealant.
c. PVC pipe —Seal alljoints usingPVC ce-
ment.
 Exceptwhere noted otherwise
above, seal air piping using either
the sealant specified by the vent pipe
manufacturer for vent joints or one
of the following silicone sealants:
 •DowCorning700™or732™
 •GeneralElectric108or800
2. Combustionairpipemaybepitchedslightlytoward
outside termination to preent rain from entering
boiler.
Support the air piping in the same
manner as specified for the vent pipe
bytheventpipemanufacturer.Do
not support the air pipe from the
sidewall termination.
Venting multiple GV boilers
 Donotconnectmultipleboilersto
the same vent. Failure to comply
could result in severe personal
injury, death or substantial property
damage.
Sidewall
Space terminations apart as shown in the figure
below.
Vertical
MultipleGVboilersmaybeverticallyventedwithvent
terminations at the same height. Maintain spacing as
noted in the figure below.

Part number 550-141-923/0710 7
GOLD GV Series 3 & 4 — Venting Supplement for 3.00” venting
Installation — assembly continued
Figure 10 Sidewall termination installation (non-direct venting)
Saf-T Vent®
CORR/GUARDFasNSeal™
3V009
Sealant
Pipe
section
Band clamp
Metal plate
Metal plate
Termination coupling
Spacer to support
sleeve on vent
18" Slip
connector, 3"
¼" to ¾" between stop on
termination and metal plate
Spacers (2)
(to support
and center
vent in
sleeve)
Z-Vent II
4" galvanized sleeve
(through 4"hole for
wall)
¹⁄₈
combustible
Spacers (2)
(to support and
center vent in
sleeve)
Termination coupling
Sealant
Sealant
Pipe section
Pipe section
Metal plate
Metal plate
4" galvanized sleeve (through
4"hole forwall)¹⁄₈ combustible
Pipe section
Metal plate
Spacers (2)
(to support and
center vent in
sleeve)
Metal plate
Pipe section
Termination coupling
Sealant
Sealant
¼" to ¾" between stop on
termination and metal plate
¼" to ¾" between stop on
termination and metal plate
¼" to ¾" between stop on
termination and metal plate
4" galvanized sleeve
(through 4"hole for
wall)
¹⁄₈
combustible
Pipe section
Metal plate
Spacers (2)
(to support and
center vent in
sleeve)
Metal plate
Pipe section
Termination coupling
4" galvanized sleeve (through
4"hole forwall)¹⁄₈ combustible

GOLD GV Series 3 & 4 — Venting Supplement for 3.00” venting
Installation — assembly continued
Figure 11 Installation of condensate tubing
8Part number 550-141-923/0710
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.
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-prole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.