Weil-McLain Gold GV Manuel utilisateur

GOLDGOLD

GOLD

PartNo.550-141-856/0703

Water Boiler — Series 4

GVGV

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 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 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 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 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.

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 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)

Ce manuel convient aux modèles suivants

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