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:

11Part number 550-141-850/0699
•Installation •Start-Up •Parts •Maintenance
Figure 2
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.
Boiler
top
Boiler
side
Front Front
10"
min
1"
min
1"
min
1"
min
1" min
4"
min
4"
min
Access door
Access
with fresh air
openings
DOOR
Area adjacent to access door must be accessible
and must allow for removal of the GV boiler for service.
No other appliance or air mover (exhaust fan, etc.)
may be mounted in the same space.
6" max
6" max
SIDE VIEW
TOP VIEW
85006b
(2) Fresh air openings —
Each with at least 1 sq. inch per 1,000 Btuh
of boiler input
Ceiling
Wall Wall
Wall
Floor
Wall
Flooring
The GV boiler is approved for installation on combustible
flooring, but must never be installed on carpeting.
Do not install boiler on carpeting even
if foundation is used. Fire can result,
causing severe personal injury, death
or substantial property damage.
Foundation
Provide a solid brick or minimum 2-inch thick concrete
foundation pad if any of the following is true:
•floor can become flooded.
•the boiler mounting area is not level.
•high profile condensate pump is used.
(Foundation thickness will depend on height
of condensate pump inlet.) Refer to separate
Weil-McLain supplement for details.
The minimum foundation size is 16" wide by:
•30¾"long for GV-3 or GV-4.
•37¾"long for GV-5 or GV-6.
Flooring and foundation
Precautions
Take the following special precautions when installing
the boiler in a residential garage. If the boiler is located in
a residential garage, per ANSI Z223.1, paragraph 5.1.9:
•Mount the boiler a minimum of 18 inches
above the floor of the garage to assure the
burner and ignition devices will be no less than
18 inches above the floor.
•Locate or protect the boiler so it cannot be
damaged by a moving vehicle.
Residential garage installation

Part number 550-141-850/069912
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 —vent system
Vent system
The GV boiler requires a special vent system, designed
for pressurized venting with likelihood of condensation
in the vent. This is referred to as ANSI Z21 Class IV,
Condensing.
You may use any of the vent systems covered by the GV
venting supplements included in the instruction manual
envelope. The GV vent starter tee is a special item designed
only for the GV boiler, available from each vendor. Do
not attempt to connect the vent to the GV boiler with any
other means.
DO NOT mix components from
different systems. The vent system
could fail, causing leakage of flue
products into the living space, causing
severe personal injury or death.
Vent termination and
combustion air supply
The GV boiler may be vented through the roof or through
a side wall. Follow the appropriate vent supplement for
the vent system chosen. The maximum vent length
depends on boiler size. Refer to the vent supplement to
verify vent length will be acceptable.
Combustion air for the GV boiler may be from inside or
ducted directly to the boiler from outside. For outside air
(direct vent installation), two options are available for
the flue/air termination. The air supply must ALWAYS
terminate at the same location as the flue, using either:
1. Vertical direct vent installation.Obtain the Through-
roof or through-unused chimney kit and
supplement. Find additional information in the vent
supplement for the venting material chosen.
2. Sidewall vent/air termination. This requires the Weil-
McLain GV vent/air intake termination kit. Refer
to the instructions packed with the kit and the vent
supplement for the venting material chosen.
Installations above 5,500 feet altitude must be
direct vent if sidewall vented.
Failure to follow all instructions
following can result in flue gas
spillage and carbon monoxide
emissions, causing severe personal
injury or death.
When removing a boiler
from an existing common vent system:
At the time of removal of an existing boiler, the following
steps shall be followed with each appliance remaining
connected to the common venting system placed in
operation, while the other appliances remaining connected
to the common venting system are not in operation.
a. Seal any unused openings in the common
venting system.
b. Visually inspect the venting system for proper
size and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion and other
deficiencies which could cause an unsafe condition.
c. Test vent system —Insofar as is practical, close
all building doors and windows and all doors between
the space in which the appliances remaining
connected to the common venting system are located
and other spaces of the building. Turn on clothes
dryers and any appliance not connected to the
common venting system. Turn on any exhaust fans,
such as range hoods and bathroom exhausts, so they
will operate at maximum speed. Do not operate a
summer exhaust fan. Close fireplace dampers.
d. Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat
so appliance will operate continuously.
e. Test for spillage at draft hood relief opening after
5 minutes of main burner operation. Use the flame
of a match or candle, or smoke from a cigarette,
cigar, or pipe.
f. After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers, and
any other gas-burning appliance to their previous
conditions of use.
Any improper operation of common venting system
should be corrected so the installation conforms with
the National Fuel Gas Code, ANSI Z223.1 —latest edition.
Id
Removing from existing vent 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.
GV special vent system

13Part number 550-141-850/0699
•Installation •Start-Up •Parts •Maintenance
Prepare boiler location —contamination
Air contamination
Please review the following information on potential
combustion air contamination problems.
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 cleaning
solvents found in household laundry rooms
Garages with workshops
Adhesives used to fasten building products and
other similar products
Table 2 Corrosive contaminants
Refer to Table 2 for products and areas which may cause
contaminated combustion air.
Ie
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. Contaminated combustion air will damage the boiler, resulting in possible severe
personal injury, death or substantial property damage. Do not install GV boiler in a laundry
room or pool facility, for example, without using ducted outside air. These areas will always
contain contaminants.

Part number 550-141-850/069914
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 —air openings
GV combustion air options
Using inside air — non-direct vent
The GV boiler can use inside air if no contaminants are
present in the boiler space.
Using outside air — direct vent
Combustion air can be ducted directly from outside to
the GV boiler air intake fitting. The installation is defined
as direct vent (also referred to as sealed combustion).
Sizing air openings
Air openings to the GV boiler space are always required,
regardless whether combustion air is taken from inside or
outside. These air openings provide for ventilation (as
well as combustion air) to prevent overheating of the
boiler controls and boiler space. Air is also needed for
other appliances located in the same space.
Use Figure 3, cases a through d, depending on how the
air is supplied and whether the space contains only the
GV or other appliances as well. The air opening sizing of
Figure 3 is based on ANSI Z223.1, National Fuel Gas
Code, intended for natural draft appliances. The GV boiler
is not natural draft, so its requirements differ.
Air openings must be sized to handle
all appliances and air movers
(exhaust fans, etc.) using the air
supply.
Louver allowance
The free area of openings means the area after reduction
for any installed louvers or grilles. Be sure to consider
this reduction when sizing the air openings.
GV with other appliances
If the GV boiler is installed in a large space (clearances per
Figure 1) providing air for a water heater or other gas
appliance, size the air openings as follows:
GV direct vent —large shared space
Provide two openings per Figure 3, based only on the size
of the other appliances and air movers. No additional air
opening area is required for the GV boiler.
GV inside air —large shared space
If the GV combustion air comes from the inside space,
size two air openings for the total of all appliances and air
movers, including the GV boiler. Use the formula from
the appropriate case in Figure 3.
Single air opening option
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.
The other appliances must all be installed with at least 1
inch clearance from the sides and back, and 6 inches from
the front. The GV boiler must have minimum clearances
as shown in Figure 1.
The single air opening may be connected from outside to
the appliance space by any of the methods of Figure 3.
The free area of the opening must also be at least equal to
the combined area of all appliance vent connectors OR
sized per the following, whichever result is larger:
GV direct vent —large shared space —
single air opening
Size the single air opening for 1 square inch of free opening
for each 3,000 Btuh of all appliances other than the GV.
No additional air opening is needed for the GV.
GV inside air —large shared space —
single air opening
Size the air opening for 1 square inch of free opening for
each 3,000 Btuh of all appliances, including the GV.
GV without other appliances
If the GV boiler is installed in a space by itself, with no
other appliance or air mover using air from the space,
and with clearances around the boiler no less than those
shown in Figure 1 for large space installations:
GV direct vent —large space —alone
Air is needed only for ventilation. Size the air openings
for any of the cases of Figure 3 for a free area of at least:
1 square inch per 8,000 Btuh of GV input
for each of the two openings. (If a single opening within
12 inches of the ceiling is used, size the opening for 1
square inch of free area for each 3,000 Btuh of GV input.)
GV inside air —large space —alone
Size the air openings for any of the cases of Figure 3 for a
free area of at least:
1 square inch per 4,000 Btuh of GV input
for each of the two openings. (If a single opening within
12 inches of the ceiling is used, size the opening for 1
square inch of free area for each 3,000 Btuh of GV input.)
If

15Part number 550-141-850/0699
•Installation •Start-Up •Parts •Maintenance
GV in small space (less than Fig. 1) —alone
For all vent/air situations, whether air is taken from inside or outside, provide
two openings, each with minimum free area of:
1 square inch per 1,000 Btuh of GV input.
The openings must be within 6 inches of the ceiling and 6 inches of the floor
as shown in Figure 2 for small space installations.
Special considerations
Tight construction
ANSI Z223.1 defines unusually tight construction where:
a. Walls and ceilings exposed to the outside atmosphere have a continuous
water vapor retarder with a rating of 1 perm or less with openings gasketed,
and . . .
b. Weatherstripping has been added on openable windows and doors, and
. . .
c. Caulking or sealants are applied to areas such as joints around windows
and door frames, between sole plates and floors, between wall-ceiling
joints, between wall panels, at penetrations for plumbing, electrical, and
gas lines, and in other openings.
For buildings with such construction, provide air openings into the building
from outside, sized per the appropriate case in Figure 3 if appliances are to
Air
Air
Air
Air
opening
Add air openings
to outside if
building is tight
construction.
Air
opening
Air
opening
Air
opening
Air (direct vent)
(optional)
Air (direct vent)
(optional)
Air (direct vent)
(optional)
0 to 12"
0 to 12"
12"
0 to 12"
0 to 12"
Flue
Flue
Flue
Other
appliances
Other
appliances
Other
appliances
Other
appliances
GV
GV
Air
Air (direct vent)
(optional)
Flue
GV
GV
Outside
Outside or ventilated attic
Air
opening
Air
opening
0 to 12"
0 to 12"
Outside
Ventilated
crawl space
—or —
a
d
b
cEach opening free area =
1 sq. inch per 4,000 Btuh Each opening free area =
1 sq. inch per 2,000 Btuh
Each opening free area =
1 sq. inch per 1,000 Btuh
Each opening free area =
1 sq. inch per 4,000 Btuh
85005
Figure 3
Air openings:
GV in space
with other
appliances
a —
Air from inside
building
b —
Air directly
from outside
c —
Air through
vertical ducts
(or inlet air
from ventilated
crawl space)
d —
Air through
horizontal
ducts
use inside air for combustion and ventilation.
Exhaust fans and air movers
The appliance space must never be under a negative
pressure, even if the appliance(s) are installed as direct
vent. Always provide air openings sized not only to the
dimensions required for the firing rate of all appliances,
but also to handle the air movement rate of the exhaust
fans or air movers using air from the building or space.
Motorized air dampers
If the air openings are fitted with motorized dampers,
electrically interlock the damper to:
•Prevent the boiler from firing if the damper is not
fully open.
•Shut the boiler down should the damper close during
boiler operation.
To accomplish this interlock, wire an isolated contact
(proving the damper open) in series with the thermostat
input to the boiler.The boiler will not start if this contact
is open, and will shut down should it open during
operation.

Part number 550-141-850/069916
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 —overview
❏Leave the boiler on its skid until installation site is ready and boiler prep is
complete per this 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.
❏Place boiler in position and install jacket rear panel.
❏Plug openings and hydrostatically test boiler. Remove plugs.
Use only the vent starter tee of the same manufacturer as the
vent components to be used. Do not mix components from different
systems. The vent system could fail, causing flue gas spillage, resulting in
severe personal injury or death.
Install vent starter tee as shown in Figure 4.
1. Remove jacket access panel (item 1). You can rotate the plate out of the way, leaving the air
hose connected to the air intake fitting, or loosen the hose clamp (item 2) and pull the air hose
off of the fitting as shown in Figure 4.
2. Remove the hex nuts (item 5) from the vent starter tee studs at the boiler vent connection.
3. Remove the vent starter tee gasket (item 4) from the studs.
4. Clean the surface of the boiler flue connection to assure a good seal. Use emery cloth if
necessary to remove any accumulated rust.
5. Place the vent starter tee gasket (item 4) over the studs.
6. Slide the holes in the vent starter tee flange (item 3) over the studs.
7. Apply the (4) hex nuts (item 5), align the vent starter tee (item 3) and tighten the nuts
uniformly.
Install condensate trap hose as shown in Figure 4.
1. Loosen and slide a spring hose clamp (item 8) over each end of the condensate drain hose
(item 6).
2. Loosen the clamp and slide one end of the hose over the CPVC drain elbow (item 7). Slide
clamp into position and release.
3. Attach and clamp the other end of the hose to the drain connection on the bottom of the vent
starter tee (item 3).
Replace jacket access panel (item 1),reconnecting the air hose to the air intake fitting if necessary.
Install vent starter
tee and condensate
drain hose
Overview of this
section
IIa
Prepare boiler —vent starter tee & drainIIb

17Part number 550-141-850/0699
•Installation •Start-Up •Parts •Maintenance
85002
The vent starter tee is NOT supplied with the boiler. Obtain this
part as a separate purchase from your Weil-McLain wholesaler.
The vent starter tee shown is for Saf-T Vent®. Use only the vent tee
made for the vent system you are using. DO NOT mix different
brands of vent system components. The vent system could fail to
operate properly, causing leakage of flue products into the living
space, resulting in severe personal injury or death.
Vent starter tee —not included
with boiler. See information
below.
Insert CPVC elbow
into bracket. Then
attach bracket to
base rail with screw
as shown at left.
Base rail
Screw hole
and notch, located
in base rail under
vent outlet
10-32 x 3/8"
Prepare boiler —vent starter tee & drain (cont.)
Figure 4 Install vent starter tee and
condensate drain hose before
placing boiler.
IIb

Part number 550-141-850/069918
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 —orifice plate
The correct orifice plate must be used. Failure to do so will result in severe
personal injury, death or substantial property damage.
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. The boiler size is stamped where the“X”is shown in the plate stamping,
Figure 5b.
Propane:Propane:
Propane:Propane:
Propane:
For propane installations, replace the silver gas/air orifice plate with the red/white
plate, per following instructions. Ensure the red/white plate boiler size is correct for the GV
boiler being installed. The boiler size is stamped where the “X”is shown in the plate stamping,
Figure 5b.
Also fill out the propane label in the conversion kit and attach to the left side of the jacket, above
the gas inlet opening, as shown in Figure 5a.
Plate installation
Access the bottom of the blower housing as shown in Figure 5a.
To inspect the plate only, read the marking on the plate edge.It must read the same as the
boiler size and fuel.
To replace the plate, using a manual screwdriver or nut driver, see Figure 5b:
1. Loosen screws 1and 2two full turns.
2. Remove screws 3and 4.
3. Pull the gas/air orifice plate forward to remove it.
4. Slide in the new plate as shown in Figure 5b. The red side of a propane plate must go
next to the blower housing as shown.
5. Replace screws 3and 4. Tighten all four screws securely and uniformly.DO NOT overtighten.
DO NOT exceed 40 inch-pounds torque.
6. Bend down plate label tab at score mark as shown in lower right corner of Figure 5b.
Check for correct
orifice plate and
replace if necessary
Remove jacket front panel to access the bottom
side of the blower housing.
Leave the boiler on its back, on the skid as
shown, until you have checked the gas/air orifice
plate and replace it if necessary.
85004a
Complete the propane conversion label included
with the conversion kit. Install label on jacket left
side, as shown.
Figure 5a
Check for correct orifice plate
and replace if necessary.
Leave boiler on its back, on
the skid, until inspection/
replacement is completed.
IIc

19Part number 550-141-850/0699
•Installation •Start-Up •Parts •Maintenance
GVX PROP
GVX PROP
GVX PROP
Install plate with red side (propane) or plain side
(natural) .against the blower housing
Orifice plate after bending along
score mark. This makes the plate
identification readable after
installation. 85004b
GVX PROP
GVX PROP
GVX PROP
Propane —red side Natural —plain side
White side (propane plate)
Warning label side (natural gas)
(Install with this side
toward air inlet hose)
Gas/air manifold
Bottom side of boiler front section
Bottom side of boiler front section
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.
Failure to properly seal the plate to
the housing could result in a gas leak,
causing severe personal injury, death
or substantial property damage.

Part number 550-141-850/069920
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 —high altitude kit
When requiredWhen required
When requiredWhen required
When required
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 Weil-
McLain distributor.This kit includes the high altitude air
pressure switch and a special tool needed for accessing
the adjusting screw on some gas valves. The kit also
includes tubing fittings as described in manual.
Obtain high altitude
kit
IId
Install high altitude
air pressure switch 1. See Figure 5c (switch shown with wires removed).
2. Remove the two (RED) control wires from the air
pressure switch spade terminals.
3. Remove the factory-installed air pressure switch
(loosen top screw and remove bottom screw holding
switch to jacket interior panel).
4. Install the high altitude air pressure switch in the same
location.
5. Carefully replace the hoses on the new switch, with
the red hose on the hose barb closest to the interior
panel, as shown in Figure 5c. The white hose goes
on the outer hose barb.
6. Replace the two (RED) control wires on the new
pressure switch spade terminals.
Check gas valve
outlet pressure After following the start-up procedures of manual Section
VII, follow the procedures of Section VIIf to measure gas
valve outlet pressure and adjust if necessary.
Failure to check gas valve
outlet pressure and adjust, if
necessary, could result in severe
personal injury,death or substantial
property damage. Carefully follow
the guidelines given in this manual.