Weil-McLain Gold GV 3 Series User manual

GOLDGOLD
GOLDGOLD
GOLD
Part No. 550-141-850/0699
Water boiler — Series 3
GVGV
GVGV
GV
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 number 550-141-850/06992
GOLD GV Water boiler series 3 — manualGOLD GV Water boiler series 3 — manual
GOLD GV Water boiler series 3 — manualGOLD GV Water boiler series 3 — manual
GOLD GV Water boiler series 3 — manual
①Control 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.
After a 15-second warmup, the GCM opens the gas valve, turns the igniter off, and checks for
flame. The flame must come on within 4 seconds or the GCM will shut down and try the full cycle
again.
When the room thermostat is satisfied, the GCM turns off the boiler components and waits for the
next heat call.
The GCM indicator lights show normal sequence when the lights are on steady. When a problem
occurs, the GCM flashes combinations of lights which indicate the most likely reason for the
problem.
②Transformer
The control transformer reduces line voltage to 24 volts for the gas valve and limit circuit.
③Blower
The blower pulls in air and mixes it with gas from the gas valve. The blower forces this mixture into
the burner for combustion inside the boiler chamber.
④Air pressure switch
The air pressure switch signals the control module, telling the control module whether air is
moving through the blower.
⑤Water temperature limit switch
The water temperature limit switch turns off the gas valve if the temperature in the boiler goes
above its setting. (The circulators will continue to run as long as there is a call for heat.)
⑥System circulator
The system circulator circulates water through the external (system) piping. The flow rate of the
circulator is controlled by the GCM, depending on the temperature of the water entering the boiler
sections.
⑦Bypass circulator
The GCM operates the bypass circulator to mix hot water from the boiler outlet with colder return
water from the system as needed to prevent condensation of flue gases in the boiler.
When the water returning to the boiler is below 130 °F, the GCM regulates the bypass circulator
and system circulator flow rates to raise the return water temperature up to 130 °F before it enters
the boiler sections. By balancing these flow rates, the GCM can protect against condensation even
if return water is as low as 60 °F.
⑧Water temperature sensor
The water temperature sensor monitors the temperature of the water entering the boiler sections.
The sensor sends this information to the GCM. The GCM determines how much to adjust the
circulator flow rates to provide at least 130 °F entering water.
How it works . . .

3Part number 550-141-850/0699
Ž Installation • Start-Up • Parts • Maintenance
85001
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
pressure/temperature gauge
flueway inspection port cover
sensor hose trap
manual air vent
j relief valve
Thisboilerusesa
gasvalve,setforanoutlet
pressure approximately w.c..
set the outlet pressure higher than
factory setting.
negative-pressure-
regulated
–0.20" DO
NOT
GOLD GV Water boiler —Series 3

Part number 550-141-850/06994
GOLD GV Water boiler series 3 —manualGOLD GV Water boiler series 3 —manual
GOLD GV Water boiler series 3 —manualGOLD GV Water boiler series 3 —manual
GOLD GV Water boiler series 3 —manual
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.
Hazard definitions
Please read before proceeding
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.
Table of contents See pages 6 and 7 for Table of contents.
User •This manual is for use only by your qualified heating installer/
service technician.
•Please refer to the User’s information manual for your reference.
•We recommend regular service by a qualifed service technician,
at least annually.
Installer Read all instructions before installing. Follow all
instructions in proper order to prevent personal injury
or death.
•Also refer to GV Series 3 Venting supplements.
•Consider piping and installation when determining boiler location.
•Any claims for damage or shortage in shipment must be filed
immediately against the transportation company by the consignee.

5Part number 550-141-850/0699
•Installation •Start-Up •Parts •Maintenance
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.
•Should overheating occur or gas supply fail to shut off, do not
turn off or disconnect electrical supply to pump. Instead, shut off the
gas supply at a location external to the appliance.
•Do not use this boiler if any part has been under water.
Immediately call a qualified service technician to inspect the boiler and to
replace any part of the control system and any gas control, which has
been under water.
Boiler water —
•DO NOT use petroleum-based cleaning or sealing compounds in
boiler system.Water seal deterioration will occur, causing leakage between
sections. This can result in substantial property damage.
•DO NOT use "homemade cures" or "boiler patent medicines".
Serious damage to boiler, personnel and/or property may result.
•Continual fresh makeup water will reduce boiler life. Mineral
build-up in sections reduces heat transfer, overheats cast iron,and causes
section failure. Addition of oxygen and other gases can cause internal
corrosion. Leaks in boiler or piping must be repaired at once to prevent
makeup water.
•Do not add cold water to hot boiler. Thermal shock can cause
sections to crack.
Please read before proceeding

Part number 550-141-850/06996
GOLD GV Water boiler series 3 —manualGOLD GV Water boiler series 3 —manual
GOLD GV Water boiler series 3 —manualGOLD GV Water boiler series 3 —manual
GOLD GV Water boiler series 3 —manual
Contents
Contents Summary Pages
I. Prepare boiler location • 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
II. Prepare boiler Leave boiler on its skid until preparation complete.
Install vent starter tee.
Inspect/replace if necessary the gas/air orifice.
Install high altitude kit (over 5,500 feet).
Place boiler in position.
Hydrostatically test boiler.
16 – 25
III. Water piping Select system type from navigation table on page 26, cover-
ing baseboard systems, radiator systems, radiant heating
systems, heat pump systems, snow melt systems and water
chiller systems.
Review boiler connections pages 28 – 29, including instal-
lation of air separator and expansion tank.
Review general system information, page 30.
Obtain any system components needed but not on hand at
the job site.
Install relief valve and discharge piping.
Connect system piping.
Install low water cutoff and additional limit control, if
required.
26 – 36
IV. Venting and combustion air Refer to Vent supplements included with boiler 37
V. Gas piping Connecting gas supply, including need for pipe supports.
Natural gas boilers — gas line sizing (for 0.3" w.c. drop).
Propane boilers — refer to gas supplier.
38 – 39
VI. Field wiring Code compliances.
Wiring must be N.E.C. Class 1.
Thermostat connections.
Junction box installation.
Field wiring diagram.
40 – 41

7Part number 550-141-850/0699
•Installation •Start-Up •Parts •Maintenance
Contents
Contents Summary Pages
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).
42 –47
VIII.Check-out procedure Complete checklist and fill out certificate. 48 –49
IX. Operation GCM (control module) indicator lights and sequence of opera-
tion.
Ladder wiring diagram (page 52).
Schematic wiring diagram (page 53).
Lighting instruction sheet —boiler with Robertshaw 7200DERN
gas valve (page 54).
Lighting instruction sheet —boiler with White-Rodgers 36E gas
valve (page 55).
50 –55
X. Service and maintenance Service/maintenance schedule table (page 57).
Detailed instructions for annual start-up and service.
Special procedures for condensate drain line check valve (page
63, if needed) and cleaning boiler heating surfaces (page 64).
56 –65
XI.Troubleshooting Troubleshooting procedures (page 67).
Checking air pressure switch (page 68).
Servicing tips and precautions —Igniter, gas valve and blower
housing (page 69).
Servicing tips and precautions plus indicator lights and lockout
modes of GCM (control module) (page 70).
Common problems and solutions (pages 72 and 73).
Troubleshooting based on GCM indicator lights (pages 74 –81).
66 –81
XII. Replacement parts Accessory bag assembly shipped with boiler (page 83).
Section assembly parts (page 84).
Jacket assembly parts (page 86).
Blower assembly parts (page 88).
Trim assembly parts (page 90).
Interior panel parts (page 92).
82 –93
XIII.Dimensions and ratings Dimensional drawing and boiler rating table. 94 –95

Part number 550-141-850/06998
GOLD GV Water boiler series 3 —manualGOLD GV Water boiler series 3 —manual
GOLD GV Water boiler series 3 —manualGOLD GV Water boiler series 3 —manual
GOLD GV Water boiler series 3 —manual
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.
❏Check the boiler space to be sure minimum clearances and accessibility
are available.
❏Obtain special venting materials and make sure vent will comply with
instructions.
❏Direct vent installation (outside air piped to boiler) is optional in most
cases. But, if air contamination is likely, you will have to pipe air to the
boiler. Note list of contaminants on page 13.
❏If the GV boiler is replacing a boiler being removed from a combined vent
system that will still serve other appliances, follow the procedure in this
manual to verify vent performance.
Ia

9Part number 550-141-850/0699
•Installation •Start-Up •Parts •Maintenance
•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 forAutomatically 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. C22.1 Canadian
Electrical Code Part 1 and any local codes.
The GV boiler gas manifold and controls met safe lighting and other performance criteria when
boiler underwent tests specified in ANSI Z21.13 —latest edition.
Altitude
(feet) % Sea level input
1,000 97
2,000 93
3,000 90
4,000 87
5,000 83
5,500 82
6,000 80
7,000 77
8,000 74
9,000 72
10,000 69
Table 1
Estimated GV input at altitude
Prepare boiler location —codes & altitudeIb
Installations must
follow these codes:
High altitude
installations GV boiler controls automatically reduce input with increasing altitude. See Table 1 for estimated
input at altitude as a percentage of sea level input. Multiply the boiler sea level input by this
percentage to obtain the estimated high altitude input. Note that the length of the venting system
will also have a minor impact on input. Refer to the vent supplement for further information.
No modifications to the boiler should be necessary for installations up to 5,500 feet above sea
level. For higher elevations, the air pressure switch must be changed to a special high altitude
switch. Refer to the high altitude kit instructions, manual Section IId. Note that the gas valve
outlet pressure must be checked (and adjusted if necessary) in accordance with manual Section
VIIf.
At altitudes above 5,500 feet, GV boilers can be sidewall vented only when
using direct vent (ducted combustion air). GV boilers can be vertically vented
in any of the configurations shown in the vent supplements. Refer to vent
supplements for more detail.

Part number 550-141-850/069910
GOLD GV Water boiler series 3 —manualGOLD GV Water boiler series 3 —manual
GOLD GV Water boiler series 3 —manualGOLD GV Water boiler series 3 —manual
GOLD GV Water boiler series 3 —manual
Large space
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.
•The space will probably be large enough for most
service and maintenance to be done in place.
Small space
You can install the boiler in a space smaller than Figure 1,
but no smaller than shown in Figure 2 —this is called a
small space installation.
•Air openings to a small space must provide at least 1
square inch free area for every 1,000 Btuh of boiler
input (at least 75 sq. in. for GV-3, 105 sq. in. for GV-
4, 140 sq. in. for GV-5 or 175 sq. in. for GV-6). The air
opening free area must be at least this size even if the
boiler uses outside air.
•Air openings have to be within 6 inches of the floor
and 6 inches of the ceiling of the space to prevent
overheating of boiler internal components.
•Provide at least screwdriver clearance to jacket front
panel screws for removal of front panel for inspection
and minor service.
•The boiler cannot be serviced in place. Pipe the
boiler with unions and isolation valves so it can be
slid out of the space and serviced in an adjacent area.
The space has to be equipped with a door so boiler
can be accessed, unpiped and removed.
•No other appliance or air handler can be installed in
the same space or share its air supply.
Prepare boiler location —clearances
Boiler
front
Boiler
front
36"
min
36"
min
36"
min
36"
min
6"
min
6"
min
6"
min
TOP VIEW
FRONT VIEW
Wall
Ceiling
Wall
Wall
Wall
Wall
Wall or obstruction
85006a
Floor
Figure 1
Large space — minimum clearances between
boiler and walls or obstructions as below; see
Section Ie for minimum combustion/ventilation
air opening sizing.
Ic
Install the boiler so control system
components are protected from
dripping or spraying water or
rain during operation. Allowing
these components to become wet
could cause a boiler failure, resulting
in severe personal injury, death or
substantial property damage.
Clearance options: