Weil-McLain Gold GV User manual

GOLDGOLD
GOLDGOLD
GOLD
PartNo.550-141-856/0703
Water Boiler — Series 4
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.

GOLD GV WGOLD GV W
GOLD GV WGOLD GV W
GOLD GV Water Boiler — Series 4ater Boiler — Series 4
ater Boiler — Series 4ater Boiler — Series 4
ater Boiler — Series 4
Partnumber550-141-856/07032
①Control module
The GOLD Control Module (GCM) responds to signals from the room thermostat, air pressure
switch,inletwatersensor andboiler limitcircuit tooperate thecirculators, gasvalve, igniterand
blower.Whenaroomthermostatcalls forheat,theGCM startsthe systemcirculatorandblower.
The GCM runs the blower to purge the boiler flue passages, then turns on the igniter and lets it
warmup.
After a 15-second warmup, the GCM opens the gas valve, turns the igniter off, and checks for
flame.Theflamemustcomeonwithin4secondsortheGCMwillshutdownandtrythefullcycle
again.
Whentheroomthermostatissatisfied,theGCMturnsofftheboilercomponentsandwaitsforthe
next heat call.
TheGCMindicator lightsshownormal sequencewhenthelights areonsteady.Whenaproblem
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
Thesystem 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. Pump must remain on boiler — do not remove.
⑦Bypass circulator
TheGCMoperatesthebypasscirculatortomixhotwaterfromtheboileroutletwithcolderreturn
water from the system as needed to prevent condensation of flue gases in the boiler.
When the water returning to the boiler is below 140 °F, the GCM regulates the bypass circulator
andsystemcirculatorflowratestoraisethereturnwatertemperatureupto140°Fbeforeitenters
theboilersections.Bybalancingtheseflowrates,theGCMcanprotectagainstcondensationeven
if return water is as low as 60 °F.
Pump must remain on boiler — do not remove.
⑧Water temperature sensor
Thewatertemperaturesensormonitorsthetemperatureofthewaterenteringtheboilersections.
The sensor sends this information to the GCM. The GCM determines how much to adjust the
circulator flow rates to provide at least 140 °F entering water.
How it works . . .

• Installation • Start-Up • Parts • Maintenance
3Partnumber550-141-856/0703
GOLD GV Water Boiler — Series 4

GOLD GV WGOLD GV W
GOLD GV WGOLD GV W
GOLD GV Water Boiler — Series 4ater Boiler — Series 4
ater Boiler — Series 4ater Boiler — Series 4
ater Boiler — Series 4
Partnumber550-141-856/07034
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.
Indicatesspecialinstructionsoninstallation,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.
• Pleasereferto the User’s Information Manual foryourreference.
• Werecommendregularservice by a qualified service technician,
at least annually.
Installer Read all instructions before installing. Follow all
instructionsin proper order to preventpersonalinjury
or death.
• Alsoreferto GV Series 3 and 4Venting Supplements.
• Considerpiping and installation whendeterminingboilerlocation.
• Any claims for damage or shortage in shipment must be filed
immediately against the transportation company by the consignee.

• Installation • Start-Up • Parts • Maintenance
5Partnumber550-141-856/0703
Failuretoadheretotheguidelinesonthispagecanresultinseverepersonal
injury,deathorsubstantialpropertydamage.
Theboilercontainsceramicfiberandfiberglassmaterials.Usecarewhen
handlingthesematerialsperinstructionsonpage82ofthismanual.Failure
tocomplycouldresultinseverepersonalinjury.
Please read before proceeding
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 supplyatalocationexternal 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
andtoreplaceanypartofthecontrolsystemandanygascontrol,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.
• Continualfreshmakeup water will reduce boiler life.Mineralbuild-
up in sections reduces heat transfer, overheats cast iron, and causes
section failure. Addition of oxygen and other gases can cause internal
corrosion.Leaksinboilerorpipingmustberepairedatoncetoprevent
makeup water.
•Do not add cold water to hot boiler.Thermalshockcancausesections
to crack.

GOLD GV WGOLD GV W
GOLD GV WGOLD GV W
GOLD GV Water Boiler — Series 4ater Boiler — Series 4
ater Boiler — Series 4ater Boiler — Series 4
ater Boiler — Series 4
Partnumber550-141-856/07036
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

• Installation • Start-Up • Parts • Maintenance
7Partnumber550-141-856/0703
Contents

GOLD GV WGOLD GV W
GOLD GV WGOLD GV W
GOLD GV Water Boiler — Series 4ater Boiler — Series 4
ater Boiler — Series 4ater Boiler — Series 4
ater Boiler — Series 4
Partnumber550-141-856/07038
Prepare boiler location — overview
❏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
areavailable.
❏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.
❏IftheGVboilerisreplacingaboilerthatisbeingremovedfromacombined
vent system that will still serve other appliances, follow the procedure in
this manual to verify vent performance.
Ia
Overview of this
section

• Installation • Start-Up • Parts • Maintenance
9Partnumber550-141-856/0703
• Local,state,provincial,nationalcodes,laws,regulationsandordinances.
• NationalFuelGasCode,ANSIZ223.1-latestedition.
• StandardforControlsandSafetyDevicesforAutomaticallyFiredBoilers,ANSI/ASMECSD-1,
whenrequired.
• NationalElectricalCode.
• For Canada only: B149.1 orB149.2 Installation Code and CSAC22.1 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.
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.Refertothehigh altitude kitinstructions,manualSectionIId.Notethatthegasvalve
outletpressuremustbechecked(andadjustedifnecessary)inaccordancewithmanualSection
VIIf.
Ataltitudes above 5,500feet, GV boilers canbe sidewall ventedonly 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.
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

GOLD GV WGOLD GV W
GOLD GV WGOLD GV W
GOLD GV Water Boiler — Series 4ater Boiler — Series 4
ater Boiler — Series 4ater Boiler — Series 4
ater Boiler — Series 4
Partnumber550-141-856/070310
Service clearances
Whenpossible,installGVboilerswithclearancesatleast
aslargeasshowninFigure1forbestserviceaccess.
Minimum clearances
YoucaninstallGVboilersinspacessmallerthanFigure1
recommendedserviceclearances.Buttheinstallationmust
always provide the minimum clearances shown in
Figure2.
• Alwaysprovideatleastscrewdriverclearancetojacket
front panel screws for removal of front panel for
inspectionandminorservice.
• If 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.
Install the boiler so control system
components are protected from
drippingor 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.
Prepare boiler location — clearances
Figure 1
Serviceclearances (recommended)
Ic

• Installation • Start-Up • Parts • Maintenance
11Partnumber550-141-856/0703
Figure 2
Minimumclearances Flooring
TheGVboilerisapprovedforinstallationoncombustibleflooring,butmust
neverbeinstalledoncarpeting.
Do not install boiler on carpeting even if foundation is
used.Firecanresult,causingseverepersonalinjury,death
orsubstantial propertydamage.
Foundation
Provideasolidbrickorminimum2-inchthickconcretefoundationpadif
anyofthefollowingistrue:
• floorcanbecomeflooded.
• theboilermountingareaisnotlevel.
• highprofilecondensatepumpisused.Provideafoundationhigh
enoughthattheGVcondensateconnectionisatleastashighas
thecondensatepumpinletconnection.
Theminimumfoundationsizeis16"wideby:
•30¾" longforGV-3orGV-4.
•37¾" longforGV-5orGV-6.
Flooring and foundation
Residential garage installation
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.

GOLD GV WGOLD GV W
GOLD GV WGOLD GV W
GOLD GV Water Boiler — Series 4ater Boiler — Series 4
ater Boiler — Series 4ater Boiler — Series 4
ater Boiler — Series 4
Partnumber550-141-856/070312
Prepare boiler location — vent system
Vent system
The GV boiler requires a special vent system, designed
forpressurizedventingwithlikelihoodofcondensation
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
eachvendor.Do not attempt to connectthe venttothe
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.
Ventterminationand
combustionairsupply
The GV boiler may be vented through the roof or
through a side wall. Follow the appropriate vent
supplementfortheventsystemchosen.Themaximum
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-McLainGV Vent/air Intake Termination Kit.
Refer to the instructions packed with the kit and
the vent supplement for the venting material
chosen. Installationsabove5,500feetaltitude
mustbedirectventifsidewallvented.
Failure to follow all instructions
following can result in flue gas
spillage and carbon monoxide
emissions, causing severe personal
injury or death.
Whenremovingaboiler
fromanexistingcommonventsystem:
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 systemforproper
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
systemarelocatedandotherspacesofthebuilding.
Turn on clothes dryers and any appliance not
connected to the commonventingsystem.Turnon
any exhaust fans, such as range hoods and
bathroom exhausts, so they will operate at
maximumspeed.Donotoperateasummerexhaust
fan. Close fireplace dampers.
d. Place in operationtheappliancebeinginspected.
Followthe lighting instructions. Adjust thermostat
so appliance will operate continuously.
e. Test for spillageatdrafthoodreliefopeningafter
5minutesof mainburneroperation.Use theflame
of a match or candle, or smoke from a cigarette,
cigar, or pipe.
f. Afterithasbeendeterminedthateach 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.Correct by resizingto approach the minimum
size as determined using the appropriate tables in Part
Id
Removing from existing vent 11ofthatcode.Canadianinstallationsmustcomplywith
B149.1orB149.2InstallationCode.
GV special vent system

• Installation • Start-Up • Parts • Maintenance
13Partnumber550-141-856/0703
Prepare boiler location — contamination
Air contamination
Please review the following information on potential
combustion air contamination problems.
Table 2 Corrosivecontaminants
RefertoTable2forproductsandareaswhichmaycause
contaminated combustion air.
Ie
If the boiler is installed in any area likely to cause contamination, or if products which
wouldcontaminatetheaircannotberemoved,youmustpipe 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.
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

GOLD GV WGOLD GV W
GOLD GV WGOLD GV W
GOLD GV Water Boiler — Series 4ater Boiler — Series 4
ater Boiler — Series 4ater Boiler — Series 4
ater Boiler — Series 4
Partnumber550-141-856/070314
Figure 3 Air opening requirements when
directexhaust venting
Prepare boiler location — air openings
GV combustion air options
Using inside air — direct exhaust venting
TheGVboilercanuseinsideairifnocontaminantsare
presentintheboilerspace.Nopipeisconnectedtotheair
intakefitting.
Using outside air — direct vent
Combustionair can be ducteddirectlyfrom outside to
theGVboilerairintakefitting.Theinstallationisdefined
asdirect vent (also referredtoassealedcombustion).
If
Sizing air/ventilation
openings
Airopeningsmustbesizedtohandle
all appliances and air movers
(exhaust fans, etc.) using the air
supply.
No other gas appliances in same space
Provideairopeningsintotheboilerspaceasdescribedin
thissectionandtheNationalFuelGasCode,ANSIZ223.1.
Directexhaust installations require air forcombustion
andventilation.Directventinstallationsmayrequireair
openingsforventilation(topreventoverheatingofboiler
controlsandboilerspace).
Whenothergasappliancessharesamespace:
Forairopeningsintospacescontainingotherappliances
inadditiontotheGVboiler(s)refertotheNationalFuel
GasCode,ANSIZ223.1forsizing.
Louver allowance
Thefreeareaofopeningsmeanstheareaafterreduction
for any installed louvers or grilles. Be sure to consider
this reduction when sizing the air openings.
Direct exhaust installations —
GV without other gas appliances
Ifdirect-exhaustventedGVboilersareinstalledinaspace
withnootherappliances,sizethecombustion/ventilation
airopeningsusingFigure3.
You may also refer to the National Fuel Gas Code for
combustion/ventilation air opening sizing.
Notice the exception given in Figure 3 for large spaces
(volume at least 50 cubic feet per 1,000 Btuh input) in
buildings other than those with tight constructions (as
described on page 15).

• Installation • Start-Up • Parts • Maintenance
15Partnumber550-141-856/0703
Special considerations —
direct exhaust or direct vent
Tightconstruction
ANSI Z223.1 defines unusually tight construction
where:
a. Walls and ceilings exposed to the outside
atmospherehaveacontinuouswatervaporretarder
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 use
inside air for combustion and ventilation.
Exhaustfans 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,butalsotohandle theairmovementrate of
the exhaust fans or air movers using air from the
building or space.
Motorizedairdampers
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.
Direct vent installations —
GV without other gas appliances
Direct-vented GV boilers installed with no other
appliances in the same space may need openings for
ventilationairasdescribedbelow.
• If direct-vented GV boilers are installed in a space
whosevolumeisatleast10ft3/1,000Btuhinput,no
ventilation openings are required.
• If direct-vented GV boilers are installed in a space
whose volume is less than 10 ft3/1,000 Btuh input,
two ventilation air openings into the space
may be necessary — one near the floor and the
other near the ceiling as shown in the illustration
below. Each opening must have a free area no less
than 1 square inch per 1,000 Btuh input of GV
boiler(s)inthespace.
• If direct-vented GV boilers are installed in a space
withclearanceslessthantherecommendedminimum
serviceclearancesshownonpage10,two ventilation
openings into the space are required — one
within6inchesofthetopofthespaceandonewithin
6inchesofthe bottom of the space.See illustration
below. Each opening must have a free area no less
than 1 square inch per 1,000 Btuh input of GV
boiler(s)inthespace.
If ventilation air openings are not
installed as directed above and the
room does not have adequate
ventilation,thehighertemperature
in the space may result in reduced
componentlife.

GOLD GV WGOLD GV W
GOLD GV WGOLD GV W
GOLD GV Water Boiler — Series 4ater Boiler — Series 4
ater Boiler — Series 4ater Boiler — Series 4
ater Boiler — Series 4
Partnumber550-141-856/070316
Prepare boiler — overview
❏Leave the boiler on its skid until installation site is ready and boiler prep
iscompleteperthis 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 5,500 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
manufacturers.Theventsystemcouldfail,causingfluegasspillage,resulting
inseverepersonalinjuryordeath.
Install vent starter tee as shown in Figure 4.
1. Removejacketaccesspanel(item1).You canrotatetheplateout of theway,leavingthe air
hoseconnectedtotheairintakefitting,orloosenthehoseclamp(item2)andpulltheairhose
offofthefittingasshowninFigure4.
2. Removethehexnuts(item5)fromtheaccessorybagassembly.
3. Removetheventstarterteegasket(item4)fromtheaccessorybagassembly.
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. Slide the two triangular reinforcing plate sections (item 9) over the studs.
8. Applythe(4)hexnutsandwashers(item5),aligntheventstartertee(item3)andtighten
the nuts uniformly.
InstallcondensatetraphoseasshowninFigure4.
1. Loosenand slide a springhose clamp (item 8)overeachend 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
ventstartertee(item3).
4. Replacejacketaccesspanel(item1),reconnectingtheairhosetotheairintakefitting.
Install vent starter
tee and condensate
drain hose
Overview of this
section
IIa
Prepare boiler — vent starter tee & drainIIb

• Installation • Start-Up • Parts • Maintenance
17Partnumber550-141-856/0703
Prepare boiler — vent starter tee & drain (cont.)
Figure 4 Install vent starter tee and
condensate drain hose before
placing boiler.
IIb

GOLD GV WGOLD GV W
GOLD GV WGOLD GV W
GOLD GV Water Boiler — Series 4ater Boiler — Series 4
ater Boiler — Series 4ater Boiler — Series 4
ater Boiler — Series 4
Partnumber550-141-856/070318
Prepare boiler — orifice plate
Thecorrect orifice platemustbeused.Failuretodosowillresultinsevere
personalinjury,deathorsubstantialpropertydamage.
Natural gas:
Fornatural gas installations, inspect the silver gas/air orifice plate marking. It mustbe
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
boilerbeinginstalled.Theboilersizeisstampedwherethe“X” isshownintheplatestamping,
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.
Toinspecttheplateonly,read the marking on the plate edge.Itmustreadthesameasthe
boiler size and fuel.
Toreplacetheplate,usingamanual screwdriver or nut driver,see Figure5b:
1. Loosen screws 1and 2two full turns.
2. Remove screws 3and 4.
3. Pull the gas/air orifice plate forward to remove it.
4. Slideinthenewplateasshownin Figure5b.The red side of a propane plate must go
next to the blower housingasshown.
5. Replacescrews3and4.Tightenallfourscrewssecurelyanduniformly.DO NOTovertighten.
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
Figure 5a
Check for correct orifice plate
and replace if necessary.
Leave boiler on its back, on
the skid, until inspection/
replacementis completed.
IIc

• Installation • Start-Up • Parts • Maintenance
19Partnumber550-141-856/0703
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
threadedholescouldstripout,causing
aninadequatesealoftheorificeplate.
Failure to properly seal the plate to
thehousingcouldresultinagasleak,
causingseverepersonalinjury,death
orsubstantialpropertydamage.

GOLD GV WGOLD GV W
GOLD GV WGOLD GV W
GOLD GV Water Boiler — Series 4ater Boiler — Series 4
ater Boiler — Series 4ater Boiler — Series 4
ater Boiler — Series 4
Partnumber550-141-856/070320
Prepare boiler — high altitude kit
When required (above 5,550 feet)
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.
ObtaintheGV high altitude kitfromyourlocalWeil-
McLain distributor. This kit includes the high altitude
air pressure switch.(You will need a T-40 star driver to
accessthegasvalvepressureregulatoradjustmentscrew.)
Thekitalsoincludestubingfittingsasdescribedinmanual.
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. Carefullyreplacethehosesonthenewswitch,with
thered hoseonthehosebarbclosesttotheinterior
panel,asshowninFigure5c.Thewhite hosegoes
on the outer hose barb.
6. Replace the two (RED) control wires on the new
pressure switch spade terminals.
Check gas valve
outlet pressure Afterfollowingthestart-upproceduresofmanualSection
VII,followtheproceduresofSectionVIIf tomeasuregas
valveoutletpressureandadjustif necessary.
Failure to check gas valve
outlet pressure and adjust, if
necessary, could result in severe
personalinjury,deathorsubstantial
property damage. Carefully follow
theguidelinesgiveninthismanual.