Weil-McLain 550-110-260/02002 - Manuals

Page 4 - Contents; Hazard definitions

Part number 550-110-260/0200 4 GOLD CGs Gas-Fired Water Boiler Contents Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards ofvarious risk levels or to important information concerning the life of the product. Indicates presenc...

Page 5 - Boiler Manual; Please read before proceeding; Installer; When servicing boiler —

Part number 550-110-260/0200 5 Boiler Manual Please read before proceeding Installer R e a d a l l i n s t ru c t i o n s b e fo r einstalling. Follow all instructions in proper order to prevent personalinjury or death. • Also refer to CGs Venting Supplements . • C o n s i d e r p i p i n g a n d i ...

Page 6 - Prepare boiler location —; Installations must

Part number 550-110-260/0200 6 GOLD CGs Gas-Fired Water Boiler • Local, state, provincial, and national codes, laws, regulations andordinances. • National Fuel Gas Code, ANSI Z223.1 – latest edition. • Standard for Controls and Safety Devices for Automatically FiredBoilers, ANSI/ASME CSD-1, when req...

Page 7 - Recommended clearances for service; Residential garage installation; Precautions; Provide the following clearances:; Boiler model number; Flooring and foundation; Figure 2; Minimum clearances for tight spaces

Part number 550-110-260/0200 7 Boiler Manual Prepare boiler location — clearances 1b Figure 1 Recommended clearances for service Residential garage installation Precautions Take the following special precautions when installingthe boiler in a residential garage. If the boiler is locatedin a resident...

Page 8 - Vent system; Removing from existing vent

Part number 550-110-260/0200 8 GOLD CGs Gas-Fired Water Boiler Prepare boiler location — vent system Vent system The CGs boiler requires a special vent system, designedfor pressurized venting. Model CGs-3 is rated ANSIZ21.13 C a t e g o r y I V (pressurized vent, likely to condense in the vent). Mod...

Page 9 - Corrosive contaminants; Products to avoid; Air contamination

Part number 550-110-260/0200 9 Boiler Manual Prepare boiler location — contamination Table 1 Corrosive contaminants 1d 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 a...

Page 10 - Special considerations

Part number 550-110-260/0200 1 0 GOLD CGs Gas-Fired Water Boiler Prepare boiler location — air openings 1e Special considerations Tight construction ANSI Z223.1 defines unusually tight constructionwhere: a. Wa l l s a n d c e i l i n g s e x p o s e d t o t h e o u t s i d e atmosphere have a contin...

Page 11 - Figure 3; Sizing air openings for CGs installations

Part number 550-110-260/0200 1 1 Boiler Manual Figure 3 Sizing air openings for CGs installations Outside Outside or ventilated attic Ventilated crawl space Or CGs 12” Max Duct Air from or — Lower Opening in Flooror Vertical Duct Outside Attic D Air opening Air opening Outside Inside CGs 12” Max 12”...

Page 12 - Prepare boiler —; Manifold orifice sizing; Inspect orifices and burners; Orifice replacement procedure; Location

Part number 550-110-260/0200 1 2 GOLD CGs Gas-Fired Water Boiler Place boiler/crate near position 1. Leave boiler in crate and on pallet until installation site is ready. 2. Move entire crate and pallet next to selected location. 3. Remove crate. 4. Remove boiler from pallet. Do not drop boiler or b...

Page 13 - Prepare boiler for test; Perform hydrostatic pressure test

Part number 550-110-260/0200 1 3 Boiler Manual Prepare boiler — 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 (from CGs supply tapping) and remove the boiler reliefvalve. Tem...

Page 14 - Water piping —; General piping information; Table 3

Part number 550-110-260/0200 1 4 GOLD CGs Gas-Fired Water Boiler Water piping — general information 3a General piping information If installation is to comply with ASME or Canadian requirements, anadditional high temperature limit is needed. Install control in supply piping between boiler and isolat...

Page 15 - Expansion tank; Diaphragm- or bladder-type expansion tank; Closed-type expansion tank; for piping

Part number 550-110-260/0200 1 5 Boiler Manual Water piping — single-zone system 3b Expansion tank Diaphragm-type or bladder-typeexpansion tank — Figure 4 1. Ensure expansion tank size will handle boiler and system water volume and temperature. Tank mustbe located in boiler return piping as close to...

Page 16 - Radiant heating systems

Part number 550-110-260/0200 1 6 GOLD CGs Gas-Fired Water Boiler Water piping — multiple zones 3c Piping for radiant heating systems or converted gravity systems Converted gravity (or steam) systems Whenever possible, use the primary/secondary piping shown in Figures 8 or 9 on page 19. This piping d...

Page 17 - typical piping — multiple-zone installations; Figure 6

Part number 550-110-260/0200 1 7 Boiler Manual typical piping — multiple-zone installations Figure 6 Zoning with circulators— return water 130 °F or higher. Figure 7 Zoning with zone valves— return water 130 °F or higher. 1 Boiler isolation (balancing) valves 2 Flow/check valve 3 System or zone circ...

Page 18 - piping method

Part number 550-110-260/0200 1 8 GOLD CGs Gas-Fired Water Boiler 1. Set the valves while the system is cool, setting for the coldest expected water temperature (usually 60 °F since the system will often drop to room temperature between cycles). 2. Start with valve 7a fully closed and 7b fully open. ...

Page 19 - for radiant heating or converted gravity systems; Figure 8; Zoning with circulators; Figure 9; Zoning with zone valves

Part number 550-110-260/0200 1 9 Boiler Manual primary/secondary (preferred) bypass piping — for radiant heating or converted gravity systems 1 Boiler isolation (balancing) valves 2 Flow/check valve 3 System or zone circulator 4 System temperature gauges 5 Zone valve 6 Drain valve 7 System temperatu...

Page 20 - method

Part number 550-110-260/0200 2 0 GOLD CGs Gas-Fired Water Boiler Water piping — low temp systems 3e This piping method is called a boiler-bypass because part of the circulator flow is bypassed around the boiler (through valve 7a ). This method reduces the flow rate throughout the boiler, in order to...

Page 21 - Figures 8

Part number 550-110-260/0200 2 1 Boiler Manual 1 Boiler isolation (balancing) valves 2 Flow/check valve 3 System or zone circulator 4 System temperature gauges 5 Zone valve 6 Drain valve 7 System temperature valves (see instructions to the leftfor adjusting valves) 8 Blend temperature gauge 9 Relief...

Page 22 - Valve adjustment

Part number 550-110-260/0200 2 2 GOLD CGs Gas-Fired Water Boiler Water piping — low temp systems 3f 1. Start with valve 7a fully closed and 7b fully open. 2. Gradually open valve 7a while closing valve 7b until the temperature at gauge 8 reads at least 130 °F at all times. 3. Valve 7a regulates the ...

Page 23 - and; Piping refrigeration systems

Part number 550-110-260/0200 2 3 Boiler Manual 3 System or zone circulator 7 System temperature valves (see instructions to the left foradjusting valves) 8 Blend temperature gauge 9 Relief valve 10 Automatic air vent (with diaphragm-type expansiontank), or connect to tank fitting (closed-type expans...

Page 24 - Gas piping; Connecting gas supply piping to boiler; Gas supply piping; Venting and combustion air

Part number 550-110-260/0200 2 4 GOLD CGs Gas-Fired Water Boiler Gas piping 5 Connecting gas supply piping to boiler Figure 14 Gas supply piping Venting and combustion air 4 CGs Boiler must be v e n t e d a n d s u p p l i e d w i t h combustion and ventilation air as described in Weil-McLain CGs Ve...

Page 25 - Table 4; Pipe capacity for 0.60 specific gravity natural gas; continued; valve; Gas pipe

Part number 550-110-260/0200 2 5 Boiler Manual Table 4 Pipe capacity for 0.60 specific gravity natural gas Gas piping continued 5 Natural Gas: 1. Refer to Table 4 for pipe length and diameter. Base on rated boiler input (divide by 1,000 to obtaincubic feet per hour). Table 4 is only for gas with spe...

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

Part number 550-110-260/0200 2 6 GOLD CGs Gas-Fired Water Boiler Figure 15 Field wiring connections — service switch and thermostat (or end switch) provided by installer For your safety, turn off electrical power supply at service entrancepanel before making any electricalc o n n e c t i o n s t o a...

Page 27 - preparation; Fill the system with water; drain; Verify water chemistry; Check for gas leaks

Part number 550-110-260/0200 2 7 Boiler Manual Determine if water treatment is needed Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to boiler will occur, resulting in substantial property damage. Eliminate all system leaks. Continual fresh makeupwater will ...

Page 28 - operate boiler; Inspect system water piping; Final check before starting boiler

Part number 550-110-260/0200 2 8 GOLD CGs Gas-Fired Water Boiler Start-up — operate boiler 7b Inspect system water piping After filling the boiler and systemw i t h w a te r, i n s p e c t a l l p i p i n g throughout the system for leaks. Iffound, repair immediately. Repeatthis inspection after the...

Page 29 - Typical pilot burner flame; Check burner flames; Pilot burner flame

Part number 550-110-260/0200 2 9 Boiler Manual 4. Check around the boiler for gas odor following the procedure of section 7a of this 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 ...

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

Part number 550-110-260/0200 3 0 GOLD CGs Gas-Fired Water Boiler 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 leaks? ❏ Correctly ...

Page 31 - Operation —; Control module sequence of operation — status light indications

Part number 550-110-260/0200 3 1 Boiler Manual Operation — sequence 9a Figure 18 Control module sequence of operation — status light indications 1. Read Lighting instructions on page 34. This information is also located on a label on the insideof the boiler jacket door panel. 2. Raise room thermosta...

Page 32 - Schematic wiring diagram

Part number 550-110-260/0200 3 2 GOLD CGs Gas-Fired Water Boiler Operation — wiring diagrams 9b Figure 19 Schematic wiring diagram

Page 33 - Ladder wiring diagram; MV; Power; Legend for ladder wiring diagram

Part number 550-110-260/0200 3 3 Boiler Manual Figure 20 Ladder wiring diagram 71033 1. All wiring must be installed in accordance with: A. U.S.A. — N.E.C. And any other national, state,or local code requirements.B. Canada — C.S.A. C22.1 C.E.C. Part 1 and anyother national, provincial, or local code...

Page 34 - Lighting instructions; FOR YOUR SAFETY READ BEFORE OPERATING

Part number 550-110-260/0200 3 4 GOLD CGs Gas-Fired Water Boiler Operation — lighting instructions 9c Figure 21 Lighting instructions FOR YOUR SAFETY READ BEFORE OPERATING OPERATING INSTRUCTIONS TO TURN OFF GAS TO THE APPLIANCE • Do not try to light any appliance. • Do not touch any electric switch;...

Page 35 - Table 5; Service and maintenance schedules; Service and maintenance —; Follow the; procedures given throughout this manual and in; Service technician; NNNUAL

Part number 550-110-260/0200 3 5 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 component literature shipped with the boiler. Failure to perform the service and maintenan...

Page 36 - Service & maintenance —; Reported problems

Part number 550-110-260/0200 3 6 GOLD CGs Gas-Fired Water Boiler Service & maintenance — annual start-up 10b The boiler should be inspected and started annually , at the beginning of the heating season, only by a qualified service technician . In addition, the maintenance and care of the boiler ...

Page 37 - Inducer motor

Part number 550-110-260/0200 3 7 Boiler Manual ❏ Service . . . . . . . . . . ❏ Inspect . . . . . . . . . . Inducer motor 1. With boiler power OFF , place a few drops of S.A.E. 20 motor oil in each of the two oil cups. Use only S.A.E. 20 motor oil to lubricate the inducer motor. Do notuse universal h...

Page 38 - Automatic air vent, typical

Part number 550-110-260/0200 3 8 GOLD CGs Gas-Fired Water Boiler Service & maint. — annual start-up continued 10b ❏ Start-up . . . . . . . . . 1. Start the b oiler, follow ing the inst ruct ions in manual section 7 . 2. Verify cold fill pressure is correct and that fill system is working properl...

Page 39 - Boiler relief valve; Relief valve, typical

Part number 550-110-260/0200 3 9 Boiler Manual circulation of air-saturated tank water back tothe system and prevents the air from bubblingup through the water as it returns from thesystem. • Do not use automatic air vents in systemswith closed-type tanks. The air will escape from the system instead...

Page 40 - Cleaning boiler heating surfaces

Part number 550-110-260/0200 4 0 GOLD CGs Gas-Fired Water Boiler 1. Review the User’s Information Manual with the owner. 2. Emphasize the need to perform the maintenance schedule specified in the User ’s Information Manual (and in this manual as well). 3. Remind the owner of the need to call in a li...

Page 41 - Troubleshooting —; personal injury, death or substantial property damage can result.; VERIFY PROPER OPERATION AFTER SERVICING.; a. Voltmeter that can check 120 VAC and 24 VAC.; Before troubleshooting:

Part number 550-110-260/0200 4 1 Boiler Manual Troubleshooting — procedure 11a Label all wires prior to disconnection when servicing controls. Wiringerrors can cause improper and dangerous operation. Never jumper (bypass) rollout thermal fuse element or any other deviceexcept for momentary testing a...

Page 42 - Check pressure switch setting; Manometer connections; Table 6; Pressure switch setpoint; Return to normal operation; blockage in block assembly

Part number 550-110-260/0200 4 2 GOLD CGs Gas-Fired Water Boiler Troubleshooting — air pressure switch 11b Make sure boiler water temperatureis 100 °F or cooler before startingprocedure to obtain appropriatereadings. Check pressure switch setting 1. See Figure 24 and Table 6 . 2. Remove both air pre...

Page 44 - Control module connections

Part number 550-110-260/0200 4 4 GOLD CGs Gas-Fired Water Boiler Troubleshooting — control module continued 11c Figure 25 Control module connections Indicator lights POWER TSTAT CIRC LIMIT PRESS SWITCH FLAME 120 VAC IN 120 VAC to transformer High voltage to spark electrode 24 VAC from transformer 24...

Page 45 - CHART 1; — Troubleshooting; light status

Part number 550-110-260/0200 4 5 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 in severe personal injury, deat...

Page 46 - CHART 2; lights flashing

Part number 550-110-260/0200 4 6 GOLD CGs Gas-Fired Water Boiler 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 property d...

Page 47 - CHART 3

Part number 550-110-260/0200 4 7 Boiler Manual continued CHART 3 — PRESS SWITCH & POWER lights flashing 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 property da...

Page 48 - CHART 4

Part number 550-110-260/0200 4 8 GOLD CGs Gas-Fired Water Boiler Troubleshooting — control module lights 11d • Turn off power to the boiler at service switch or breaker.• Wait at least 45 seconds.• Turn on power to boiler.• Restart boiler, following Lighting instructions in this manual ( Figure 21 ,...

Page 49 - CHART 5; light flashing and; light on steady; ALSO; — Troubleshooting failure to establish; main flame

Part number 550-110-260/0200 4 9 Boiler Manual continued • ▲ TURN OFF POWER ▲ to boiler at service switch or breaker. • Remove air inlet box cover (see Figure 27 , page 54 for location). • Verify inlet gas pressure at gasvalve: Natural gas — 5.0" w.c. min/14.0" w.c. max Propane — 11.0" w...

Page 50 - CHART 6

Part number 550-110-260/0200 5 0 GOLD CGs Gas-Fired Water Boiler Troubleshooting — control module lights 11d 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 instructions could r...

Page 51 - CHART 7; — Insufficient heat or no heat to system (

Part number 550-110-260/0200 5 1 Boiler Manual continued 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 to follow instructions could result in severe personal injury, death or ...

Page 52 - Replacement parts; Weil-McLain part numbers are found in; of this manual. Failure

Part number 550-110-260/0200 5 2 GOLD CGs Gas-Fired Water Boiler Replacement parts 12a Section assembly ................................................ 53 Base assembly .................................................... 54 Jacket assembly ................................................. 55 Trim ...

Page 58 - Dimensions; Dimensional drawing

Part number 550-110-260/0200 5 8 GOLD CGs Gas-Fired Water Boiler Dimensions 13a Figure 31 Dimensional drawing T OP VIEW 19 19 13¹¹₁₆ 28³⁄₈ 1⁵⁄₈ 4³⁄₄ 4³⁄₄ 13¹⁄₄ 11¹⁄₈ NOTE 2 NOTE 2 2³⁄₈ 2¹⁄₄ 3¹⁄₄ W A 9 12 23¹⁄₄ MODEL CGi Pressure/temperature gauge Supply piping ( ) note 1 Return piping ( ) note 1 Rel...

Page 59 - Ratings; Table 7; Boiler ratings; DOE; Notes

Part number 550-110-260/0200 5 9 Boiler Manual Ratings Table 7 Boiler ratings DOE 1 . Add “PIN” for natural gas boiler - “PIL” for propane gas boiler. 2. Based on standard test procedures prescribed by the United States Department of Energy. 3. Net I=B=R ratings are based on net installed radiation ...

Page 60 - Handling ceramic fiber and fiberglass materials; REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS; NIOSH stated First Aid.; REMOVAL OF FIBERGLASS WOOL — OR —; NIOSH stated First Aid.; Eye: Irrigate immediately

6 0 Part Number 550-110-260/0200 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Weil-McLain 500 Blaine Street Michigan City, IN 46360-2388 http://www.weil-mclain.com Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or ...