Weil-McLain 550-110-260/0107 - Manuals

Page 2 - GOLD CGs Gas-Fired Water Boiler — Boiler Manual

Part number 550-110-260/0107 GOLD CGs Gas-Fired Water Boiler — Boiler Manual How it works . . . ① Control module The control module responds to signals from the room thermostat, air pressure switch and boiler limit circuit to operate the boiler circulator, pilot burner, gas valve and inducer. When r...

Page 3 - GOLD CGs

Part number 550-110-260/0107 3 GOLD CGs Gas-Fired Water Boiler — Boiler Manual GOLD CGs Gas-Fired Induced-Draft Water Boiler

Page 4 - Contents; Hazard definitions

Part number 550-110-260/0107 4 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Contents 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. ...

Page 5 - Please read before proceeding; Installer; Glycol — potential fire hazard —

Part number 550-110-260/0107 5 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Please read before proceeding Installer Read all instructions before in-stalling. Follow all instructions in proper order to prevent personal injury or death. • Also refer to CGs Venting Supplements . • Consider piping an...

Page 6 - Prepare boiler location — codes; Installations must follow these codes:

Part number 550-110-260/0107 6 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — codes & checklist 1a Installations must follow these codes: • Local, state, provincial, and national codes, laws, regulations and ordinances.• National Fuel Gas Code, ANSI Z3.1–latest edition...

Page 7 - Prepare boiler location — clearances; SERVICE; Recommended SERVICE clearances; Flooring; Residential garage installations

Part number 550-110-260/0107 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — clearances 1b Figure 2 Required MINIMUM clearances Figure 1 Recommended SERVICE clearances (see WARNING below) Recommended SERVICE clearances (Fig. 1) 1. Provide clearances for cleaning and servici...

Page 8 - Prepare boiler location — vent system; CGs special vent system; Vent system

Part number 550-110-260/0107 8 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — vent system 1c Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death. When removing boiler from an existing com...

Page 9 - Prepare boiler location — contamination

Part number 550-110-260/0107 9 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — contamination 1d Table 1 Corrosive or destructive contaminants and likely locations To prevent potential of severe personal injury or death, check for products or areas listed below before instal...

Page 10 - Prepare boiler location — air openings; Special considerations; The free area of openings means the area

Part number 550-110-260/0107 10 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air openings 1e Special considerations Tight construction ANSI Z3.1 defines unusually tight construction where:1. Walls and ceilings exposed to the outside atmo- sphere have a continuous water v...

Page 12 - Prepare boiler — placement & setup; Inspect orifices and burners; Orifice replacement procedure

Part number 550-110-260/0107 1 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Place boiler/crate near position 1. Leave boiler in crate and on pallet until installation site is ready. . Move entire crate and pallet next to selected loca- tion. 3. Remove crate.4. Remove boiler from pallet. Do not dr...

Page 13 - Prepare boiler — pressure test; Hydrostatic pressure test; Prepare boiler for test; Drain and remove fittings

Part number 550-110-260/0107 13 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Prepare boiler — pressure test 2b Hydrostatic pressure test Pressure test boiler before attaching water or gas piping (except as noted below) or electrical supply. Prepare boiler for test 1. Remove the shipping nipple (f...

Page 14 - Water piping — general information; General piping information

Part number 550-110-260/0107 14 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Water piping — general information 3a Table 3 Water pipe size (based on 20°F rise) General piping information If installation is to comply with ASME or Canadian requirements, an ad- ditional high temperature limit is nee...

Page 15 - Water piping — single-zone system; Closed-type expansion tank

Part number 550-110-260/0107 15 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Water piping — single-zone system 3b Figure 4 Diaphragm- or bladder-type expansion tank Piping to single-zone system See Table 3 for piping sizes. Figure 5 Closed-type expansion tank Piping to single-zone system See Tabl...

Page 16 - Water piping — multiple zones; Piping multiple zones; Radiant heating systems

Part number 550-110-260/0107 16 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Water piping — multiple zones 3c Piping multiple zones Follow instructions on pages 14 and 15 to install near-boiler or single-zone piping. (Also refer to Piping for radiant heating systems or converted gravity sys-tems ...

Page 18 - Piping — low temp systems; bypass piping method; Temperature gauges

Part number 550-110-260/0107 18 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Piping — low temp systems 3d Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners, resulting in severe personal injury, death or substantial property damag...

Page 20 - Valve adjustment

Part number 550-110-260/0107 0 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners, resulting in severe personal injury, death or substantial property damage. Radiant heating system pipi...

Page 23 - Water piping — refrigeration systems; Prevent chilled water from entering

Part number 550-110-260/0107 3 GOLD CGs Gas-Fired Water Boiler — Boiler Manual 3 System or zone circulator 7 System temperature valves (see instructions to the left for adjusting valves) 8 Blend temperature gauge 9 Relief valve 10 Automatic air vent (with diaphragm-type expan- sion tank), or connect...

Page 24 - Venting and combustion air

Part number 550-110-260/0107 4 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Venting and combustion air 4 CGs Boiler must be vented and supplied with combus- tion and ventilation air as described in Weil-McLain CGs Venting Supplements packed in envelope as- sembly with boiler. Failure to do so wil...

Page 25 - Gas piping; Connecting gas supply piping to boiler

Part number 550-110-260/0107 5 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Gas piping 5 Table 4 Pipe capacity for 0.60 specific gravity natural gas Natural Gas: 1. Refer to Table 4 for pipe length and diameter. Base on rated boiler input (divide by 1,000 to obtain cubic feet per hour). Table 4 i...

Page 26 - Field wiring; Thermostat; Wiring connections; POWER

Part number 550-110-260/0107 6 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Field wiring 6 Thermostat 1. Connect thermostat as shown on wiring diagram on boiler. . Install on inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, television, sunrays, or fireplaces...

Page 27 - Start-up — preparation; Fill the system with water; Determine if water treatment is needed; Verify water chemistry; Check for gas leaks

Part number 550-110-260/0107 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Start-up — preparation 7a Fill the system with water 1. Close manual and automatic air vents and boiler drain cock. . Fill to correct system pressure . Correct pressure will var y with each application. Typical cold water f...

Page 28 - Start-up — operate boiler; Inspect system water piping; Start the boiler; Inspect base insulation

Part number 550-110-260/0107 8 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler 7b Inspect system water piping After filling the boiler and system with water, inspect all piping throughout the system for leaks. If found, repair immediately. Repeat this inspection after the b...

Page 29 - Check burner flames; Pilot burner flame; Main burner flame

Part number 550-110-260/0107 9 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler (continued) 7b Figure 16 Typical pilot burner flame Figure 17 Typical main burner flame Check burner flames View pilot and main flames through the inspection port in the Air inlet box front cover...

Page 30 - Check-out procedure — checklist; Installation and service certificate

Part number 550-110-260/0107 30 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Check-out procedure — checklist 8 ❏ Boiler and heat distribution units filled with water? ❏ Automatic air vent, if used, open one full turn? ❏ Air purged from system? ❏ Air purged from gas piping? Piping checked for leak...

Page 31 - Operation — sequence

Part number 550-110-260/0107 31 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Operation — sequence 9a Figure 18 Control module sequence of operation — status light indications 1. Read appropriate Operating instructions in Section 9c . This information is also located on a label on the inside of th...

Page 32 - Operation — wiring diagrams

Part number 550-110-260/0107 3 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Operation — wiring diagrams 9b Figure 19 Schematic wiring diagram

Page 34 - Operating instructions

Part number 550-110-260/0107 34 GOLD CGs Gas-Fired Water Boiler — Boiler Manual 9c Operating instructions CGs-3 to CGs-6 • Spark pilot • Natural or propane gas• Gas valve: Honeywell VR8204/VR8304

Page 37 - Service and maintenance — schedule; VERIFY PROPER OPERATION AFTER SERVICING

Part number 550-110-260/0107 3 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Table 5 Service and maintenance schedules Service and maintenance — schedule 10a Follow the Service and maintenance procedures given throughout this manual and in com- ponent literature shipped with the boiler. Failure to...

Page 39 - Burners, base and inlet air box; Condensate drain system

Part number 550-110-260/0107 39 GOLD CGs Gas-Fired Water Boiler — Boiler Manual ❏ Inspect . . . Burners, base and inlet air box The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 68 of this manual. Failure to comply could resul...

Page 40 - Limit controls and cutoffs

Part number 550-110-260/0107 40 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Service & maint. — annual start-up continued 10b ❏ Check/test . . . Gas piping 1. Sniff near floor and around boiler area for any in- dication of a gas leak . . Test gas piping using bubble test, per Section 5 of thi...

Page 41 - Boiler relief valve

Part number 550-110-260/0107 41 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Safety relief valves should be reinspected AT LEAST ONCE EVERY THREE YEARS , by a licensed plumbing contractor or authorized inspection agency, to ensure that the product has not been affected by corrosive water conditio...

Page 42 - Cleaning boiler

Part number 550-110-260/0107 4 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Service & maint. — annual start-up 10b ❏ Review with owner 1. Review the User’s Information Manual with the owner. . Emphasize the need to perform the maintenance schedule specified in the User’s Information Manual (a...

Page 43 - Troubleshooting — procedure; Before troubleshooting:

Part number 550-110-260/0107 43 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — procedure 11a Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Never jumper (bypass) rollout thermal fuse element or any other de...

Page 44 - Troubleshooting — air pressure switch; Air pressure switch; Check pressure switch setting; Troubleshooting air pressure reading; Return to normal operation

Part number 550-110-260/0107 44 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — air pressure switch 11b Air pressure switch Make sure boiler water temperature is 100 °F or cooler before starting procedure to obtain appropriate readings. Check pressure switch setting 1. See Figure 2...

Page 45 - Troubleshooting — control module; Control module; Troubleshooting the control module

Part number 550-110-260/0107 45 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module 11c Control module Solder or water splatter between plugs and circuit board can cause improper operation of control module. Place a shield over the boiler internal controls and components...

Page 47 - Troubleshooting — control module lights; CHART 1; POWER light status

Part number 550-110-260/0107 4 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights 11d CHART 1 — Troubleshooting POWER light status Electrical shock hazard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions. Failure to follow instructions could result...

Page 48 - CHART 2

Part number 550-110-260/0107 48 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights 11d Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial...

Page 49 - CHART 3; PRESS SWITCH & POWER; lights flashing

Part number 550-110-260/0107 49 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights (cont.) 11d CHART 3 — PRESS SWITCH & POWER lights flashing Electrical shock hazard — Wherever you see s TURN OFF POWER s , follow the instructions. Failure to follow instructio...

Page 50 - CHART 4

Part number 550-110-260/0107 50 GOLD CGs Gas-Fired Water Boiler — Boiler Manual 11d Troubleshooting — control module lights (cont.) • Turn off power to the boiler at service switch or breaker. • Wait at least 45 seconds. • Turn on power to boiler. • Restart boiler, following Operating instructions i...

Page 51 - CHART 5; light flashing and; light on steady; ALSO; — Troubleshooting failure to establish; main flame

Part number 550-110-260/0107 51 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights (cont.) 11d • TURN OFF POWER to boiler at service switch or breaker. • Remove air inlet box cover (see Figure 27 , page 56 for location). • Verify inlet gas pressure at gas valve: ...

Page 52 - CHART 6; PRESS SWITCH

Part number 550-110-260/0107 5 GOLD CGs Gas-Fired Water Boiler — Boiler Manual 11d Troubleshooting — control module lights (cont.) CHART 6 — PRESS SWITCH light flashing and POWER light on steady Electrical shock hazard — Wherever you see � TURN OFF POWER �, follow the instructions. Failure to follow...

Page 53 - CHART 7

Part number 550-110-260/0107 53 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights (cont.) 11d CHART 7 — Insufficient heat or no heat to system ( POWER light on steady) Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions. Failure t...

Page 54 - Replacement parts

Part number 550-110-260/0107 54 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Replacement parts 12a Section assembly .............................................. 55 Base .................................................................. 56 Jacket ....................................................

Page 55 - Replacement parts — section assembly

Part number 550-110-260/0107 55 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Replacement parts — section assembly 12b Figure 26 Section assembly

Page 56 - Replacement parts — base

Part number 550-110-260/0107 56 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Replacement parts — base 12c Figure 27 Base assembly

Page 58 - Replacement parts — jacket

Part number 550-110-260/0107 58 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Replacement parts — jacket 12d Figure 28 Jacket assembly

Page 60 - Replacement parts — trim

Part number 550-110-260/0107 60 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Replacement parts — trim 12e Figure 29 Trim assembly Itemnumber Description Manufacturer Manufacturer’s part number Weil-McLain part number 1 Pressure relief valve, ASME, 30 PSIG, ¾" male inlet Pressure relief valve,...

Page 61 - Replacement parts — controls

Part number 550-110-260/0107 61 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Replacement parts — controls 12f Figure 30 Gas control assembly Itemnumber Description Manufacturer Manufacturer’spart number Weil-McLain part number Natural gas components 1 Gas valve, ½" x ½", CGs-3 through CGs...

Page 62 - Dimensions

Part number 550-110-260/0107 6 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Dimensions 13a Figure 31 Dimensional drawing

Page 63 - Ratings; DOE

Part number 550-110-260/0107 63 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Ratings Table 7 Boiler ratings DOE 13b (Note 5) CGs boilers for residential radiant panel systems, converted gravity heating systems or other low water tempera- ture applications should be installed with balancing valves...

Page 64 - Handling ceramic fiber and fiberglass materials

64 Part Number 550-110-260/0107 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or base insulation panels in this prod- uct contain ceramic fiber materials. Ceramic fiber...