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GOLD GOLD GV GV
GOLD GV
GOLD GOLD GV GV
Water boiler — Series 3
Boiler manual
• Installation
Maintenance
Start-Up
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 No. 550-141-850/0699
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GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual GOLD GV Water boiler series 3 — manual How it works . . . Control 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
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Ž Installation Start-Up Parts Maintenance GOLD GV Water boiler — Series 3 a supply to system f pressure/temperature gauge Thisboilerusesa negative-pressure- b return from system g flueway inspection port cover regulated gasvalve, set foran outlet c combustion air inlet fitting h sensor hose trap pressure approximately –0.20" w.c.. DO d flue outlet i manual air vent NOT set the outlet pressure higher than e gas valve (see warning, right) j relief valve factory setting. 85001 Part number 550
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GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 — — — — — manual manual manual manual manual Please read before proceeding Hazard definitions 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. Indicates presence of hazards that will cause severe personal i
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Installation Start-Up Parts Maintenance Please read before proceeding 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
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GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 — — — — — manual manual manual manual manual Contents Contents Summary Pages I. Prepare boiler location • Verify code compliance. 8 – 15 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
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Installation Start-Up Parts Maintenance Contents Contents Summary Pages VII.Start-up Determine water treatment needs, if any. 42 – 47 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). VIII.Check-out procedure Complete checklist and
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GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 — — — — — manual manual manual manual manual Ia 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 instruction
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Installation Start-Up Parts Maintenance Ib Prepare boiler location — codes & altitude Installations must Local, state, provincial, and national codes, laws, regulations and ordinances. follow these codes: National Fuel Gas Code, ANSI Z223.1- latest edition. Standard for Controls and Safety Devices for Automatically 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 Electr
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GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 — — — — — manual manual manual manual manual Ic Prepare boiler location — clearances Clearance options: Figure 1 Large space — minimum clearances between Large space boiler and walls or obstructions as below; see Section Ie for minimum combustion/ventilation The boiler space must be at least as big as shown in air opening sizing. Figure 1 to qualif
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Installation Start-Up Parts Maintenance Figure 2 Flooring and foundation Small space — installation with less clearance Flooring than Figure 1 – BUT – no less than below; air openings for combustion/ventilation must be The GV boiler is approved for installation on combustible as shown below even for direct vent system. flooring, but must never be installed on carpeting. TOP VIEW Do not install boiler on carpeting even Wall if foundation is used. Fire can result, Access DOOR causing sever
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GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 — — — — — manual manual manual manual manual Id Prepare boiler location — vent system Correct by resizing to approach the minimum size as Removing from existing vent determined using the appropriate tables in Part 11 of Failure to follow all instructions that code. Canadian installations must comply with CAN/ following can result in flue gas CGA B1
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Installation Start-Up Parts Maintenance Ie Prepare boiler location — contamination Air contamination Please review the following information on potential Refer to Table 2 for products and areas which may cause combustion air contamination problems. contaminated combustion air. 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
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GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 — — — — — manual manual manual manual manual If Prepare boiler location — air openings GV combustion air options Single air opening option A single air opening within 12 inches of the ceiling may be Using inside air — non-direct vent used where the GV boiler is installed in a large space The GV boiler can use inside air if no contaminants are (clea
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Installation Start-Up Parts Maintenance use inside air for combustion and ventilation. GV in small space (less than Fig. 1) — alone For all vent/air situations, whether air is taken from inside or outside, provide Exhaust fans and air movers two openings, each with minimum free area of: The appliance space must never be under a negative 1 square inch per 1,000 Btuh of GV input. pressure, even if the appliance(s) are installed as direct The openings must be within 6 inches of the ceiling
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GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 — — — — — manual manual manual manual manual IIa Prepare boiler — overview Overview of this ❏ Leave the boiler on its skid until installation site is ready and boiler prep is complete per this section. section ❏ Install vent starter tee and condensate drain line. ❏ Inspect gas/air orifice plate to verify model size and gas markings agree with boile
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Installation Start-Up Parts Maintenance IIb Prepare boiler — vent starter tee & drain (cont.) Figure 4 Install vent starter tee and condensate drain hose before placing boiler. Screw hole Base rail Insert CPVC elbow and notch, located into bracket. Then in base rail under attach bracket to vent outlet base rail with screw as shown at left. 10-32 x 3/8" Vent starter tee — not included with boiler. See information below. The vent starter tee is NOT supplied with the boiler. Obtain this par
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GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 — — — — — manual manual manual manual manual IIc Prepare boiler — orifice plate The correct orifice plate must be used. Failure to do so will result in severe Check for correct personal injury, death or substantial property damage. orifice plate and Natural gas: replace if necessary For natural gas installations, inspect the silver gas/air orifice
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GVX PROP GVX PROP GVX PROP Installation Start-Up Parts Maintenance 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 threaded holes could strip out, causing pneumatic screwdrivers to an inadequate seal of the orifice plate. remove or tighten the gas/air boss Failure to properly seal the plate to screws. Hand-tighten only, using the housing could result in a gas leak, manual screwdri
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GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 GOLD GV Water boiler series 3 — — — — — manual manual manual manual manual IId Prepare boiler — high altitude kit When required When required When required When required When required Obtain high altitude kit 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 set
