Weil-McLain Gold GV Series 4 User manual

Part number 550-141-800/0908
Water Boiler — Series 1 – 4
GOLD GV
High altitude kit instructions
(for kit part number 382-200-317)
These instructions must only be used by a qualified
installer/service technician. Read completely before
beginning the installation. Failure to follow all
instructions can cause severe personal injury, death or
substantial property damage.
Turn off gas and electricity to the boiler before working
on the boiler. Failure to do so can cause severe personal
injury, death or substantial property damage.
Do not tamper with the orifice plate as it may cause
personal injury, death or substantial property damage.
The boiler input reduction at altitude is automatic.
To the installer:
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
can cause severe personal injury,
death or substantial property
damage.
Indicates special instructions
on installation, operation or
maintenance that are important
but not related to personal injury
or property damage.
Hazard definitions
Up to 5,500 feet above sea level:
1. Use standard equipment.
2. Use standard installation instructions in GV Boiler
Manual.
3. See table below for input at altitude.
Over 5,500 feet above sea level:
1. Remove the pressure switch provided in the boiler
(Figure 1) and replace with the pressure switch
provided in the high altitude kit.
The hoses must be connected as
shown in Figure 1 — white hose
on front and red hose on back.
2. Use standard installation instructions in the GV Boiler Manual, but
venting is limited to the following (see Figure 4, page 4). The circled
numbers below reference the associated illustrations in Figure 4:
• Outsidecombustionair(DirectVent):
Through-Roof or Chimney as Raceway — using Weil-McLain
Non-Direct Vent Through-Roof Vent/Air kit.
Sidewall — using appropriate Weil-McLain vent/air
termination kit.
• Insidecombustionair(Non-DirectVent):
Through-roof — or —
Chimney as Raceway —
using Weil-McLain Non-
Direct Vent Through-
Roof termination.
Non-direct vent
sidewall applications
are not supported
for altitudes above
5,500 feet.
3. See table at left for input at
altitude.
4. For all installations over 5,500 feet
above sea level, measure and adjust
(if necessary) the gas control set
point pressure. See the following
sections for the correct procedure.
Figure 1
Pressure switch with hoses

Part number 550-141-800/0908
2
GOLD GV Series 1 – 4 High altitude kit instructions
Instructions
Measure and adjust (if necessary) gas
control set point
1. Onanyinstallationataltitudemorethan5,500feetabovesealevel,
measure the gas control set point as described below.
2. Adjust set point if necessary.
Tools needed (Figure 2)
U-tube manometer with tubing — Manometer must be type shown
in Figures 2 and 3, providing a fine scale by slanting the manometer
as shown (Dwyer Model 1227 recommended).
Tee hose fitting.
3 /16” Allen wrench.
1 /8N.P.T.-to-hose barb fitting and wrench for same.
¼" Flat head screwdriver.
T-40 Star drive for gas valve pressure regulator cover screw.
Pliers.
Connect and adjust manometer
1. Remove boiler jacket top and front panels.
2. Close manual gas supply valve and turn off electrical power to
boiler.
3. Series 1, 2 and 3 boilers:
a. Using 3 /16” allen wrench, remove outlet pressure tap plug from gas
control and save plug (Figure 3, page 3).
b. Install 1 /8N.P.T.-to-hose barb fitting in gas control outlet pressure
tap as shown in Figure 3.
c. Connect negative side manometer to hose barb fitting installed
in gas control outlet pressure tap (Figure 3, page 3).
Series 4 boilers:
a. Using flat head screw driver, remove outlet pressure tap plug from
gas control and save plug (Figure 3, page 3).
b. Connect negative side of manometer hose over end of outlet
pressure tap.
4. Position and zero manometer per manufacturer’s instructions.
The manometer hoses must extend at least 6 inches above
the manometer as shown in Figure 3, page 3. If you fail
to do this fluid from the manometer can be pulled into
the gas control, causing the gas control regulation to be
unstable.This couldresultinseverepersonalinjury,death
or substantial property damage. If manometer fluid is
drawn into gas control the gas control must be replaced.
5. Disconnect tube from hose barb on gas control vent tap. Connect tube
end to tee hose fitting as shown in Figure 3 on page 3. Then add length
of hose from tee hose fitting to gas control vent tap.
6. Connect positive side of manometer hose to hose barb tee fitting (see
Figure 3, page 3).
Check gas control set point and adjust
1. Openmanualgasvalveandturnonelectricalpowertoboiler.
2. Start boiler and allow boiler to run for 5 minutes.
3. Read manometer. This is the gas control outlet pressure set point. If
set point is between -0.1” w.c. and -0.3” w.c. go to step 6.
Figure 2 Tools needed
4. Series 1, 2 and 3 boilers:
a. If gas control set point is not between -0.1”
w.c. and -0.3” w.c., use flat head screw driver
to remove cap on adjustment tower of gas
control.
b. Turn gas contro l a djustment scre w
counterclockwise to lower gas control set
point to -0.2” w.c.
c. Reinstall cap to gas control adjustment
tower.
Series 4 boilers:
a. If gas control set point is not between -0.1”w.c.
and -0.3” w.c., use T-40 start driver to remove
cap on gas control pressure regulator.
b. Turn gas control pressure regulator screw
counterclockwise to lower gas control set
point to -0.2” w.c.
c. Reinstall cap on gas control pressure regulator
using T-40 star driver.
5. Cycle boiler off and on several times to verify gas
control set point. If set point does not remain
between -0.1” w.c. and -0.3” w.c., readjust as
necessary.
6. Close manual gas supply valve and turn off
electrical power to boiler.
7. Series 1, 2 and 3 boilers:
a. Remove 1 /8N.P.T.-to-hose barb fitting in outlet
pressure tap of gas control.
b. Apply pipe sealant to outlet pressure tap plug
and reinstall using 3 /16” allen wrench.
Series 4 boilers:
a. Remove manometer hose from gas control
outlet pressure tap barrel and replace sealing
screw.
8. Remove tee hose fitting and added tube.
9. Reinstall hose on gas control vent tap hose barb.
10. Open manual gas supply valve and turn on
electrical power to boiler.
11. Reinstall boiler jacket front and top panels.

Part number 550-141-800/0908 3
GOLD GV Series 1 – 4 High altitude kit instructions
Figure 3 Carefully connect manometer as shown, following instructions on opposite page.

Part number 550-141-800/0908
4
GOLD GV Series 1 – 4 High altitude kit instructions
Figure 4 High altitude vent options and exclusions — Installations more than 5,500 feet above sea level
Acceptable vent methods
For altitudes more than 5,500 feet above sea level
(Methods through below)
Through-roof
Non-direct vent (inside air)
Through-roof or chimney as raceway with Weil-McLain termination
Chimney as raceway
Direct vent (outside air) Sidewall with
Weil-McLain Vent/Air termination
Direct vent (outside air)
Through-roof with Weil-
McLain Vent/Air Kit
termination