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Weil-McLain 550-110-260/02002 manual

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Table of contents for the manual

  • Page 1

    [...]

  • Page 2

    P art number 550-110-260/0200 2 GOLD CGs Gas-F ired Water Boiler How it works . . . ① Control module The control module responds to signals from the room thermostat, air pressure switch and boiler limit circuit t o operate the boiler circulat or , pilot burner , gas valve and induc er . W hen room the rmostat cal ls for heat, the contr ol module [...]

  • Page 3

    [...]

  • Page 4

    P art number 550-110-260/0200 4 GOLD CGs Gas-F ired Water Boiler 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. Indicates pr esence of hazards that will cause sever e personal [...]

  • Page 5

    P art number 550-110-260/0200 5 Boiler Manual Please read before proceeding Installer Read all instr uctions befor e installing. Follow all instructions in proper order to prevent personal injury or death. • Also refer to CGs V enting Supplements . • Consider piping and installation when determining boiler location. • Any claims for damage or[...]

  • Page 6

    P art number 550-110-260/0200 6 GOLD CGs Gas-F ired Water Boiler • Local, state, provincial, and national codes, laws, regulations and ordinances. • N ational Fuel Gas Code, ANSI Z223.1 – latest edit ion. • Standard for Co nt rols and Safety De vices for A utomatically Fired Boilers, ANSI/ASME CSD-1, when required. • N ational Electrical [...]

  • Page 7

    P art number 550-110-260/0200 7 Boiler Manual P repare boiler location — clearances 1b Figure 1 Recommended clearances for service Residential garage installation Precautions T ak e 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[...]

  • Page 8

    P art number 550-110-260/0200 8 GOLD CGs Gas-F ired Water Boiler P repare boiler location — vent system Vent system The CGs boiler requires a special vent system, designed for pressurized venting. Model CGs-3 is rated ANSI Z21.13 Category IV (pressurized vent, likely to condense in the vent). Models CGs-4, -5 and -6 are rated Z21.13 Category III [...]

  • Page 9

    P art number 550-110-260/0200 9 Boiler Manual P repare boiler location — contamination T able 1 Corrosive contaminants 1d If the boiler is installed in an y area lik ely to cause contamination , or if pr oducts which would contaminate the air cannot be removed, you must pipe combustion air to the boiler air intake. Contaminat ed comb ust ion air [...]

  • Page 10

    P art number 550-110-260/0200 10 GOLD CGs Gas-F ired Water Boiler P repare boiler location — air openings 1e Special considerations Tight construction ANSI Z223.1 defines unusually tight construction where: a . W alls and ceilings exposed to the outsid e atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openin[...]

  • Page 11

    P art number 550-110-260/0200 11 Boiler Manual Figure 3 Sizing air openings for CGs installations Outside Outside or ventilated attic V entilated crawl space Or CGs 12” Max Duct Air from or — Lower Opening in Floor or V ertical Duct Outside Attic D Air opening Air opening Outside Inside CGs 12” Max 12” Max Duct Duct Air from Through horizon[...]

  • Page 12

    P art number 550-110-260/0200 12 GOLD CGs Gas-F ired 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 bump jacket on floor or pallet. Damage to boiler[...]

  • Page 13

    P art number 550-110-260/0200 13 Boiler Manual Pr epare boiler — pr essur e 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 relief valve. T emporar ily plug the relief valve tapping wi[...]

  • Page 14

    P art number 550-110-260/0200 14 GOLD CGs Gas-F ired Water Boiler W ater piping — general information 3a General piping information If installation is to comply with ASME or Canadian requirements, an additional high temperature limit is needed. Install control in supply piping between boiler and isolation valve. Set second control to minimum 20 ?[...]

  • Page 15

    P art number 550-110-260/0200 15 Boiler Manual W ater piping — single -zone system 3b Expansion tank Diaphragm-type or bladder-type expansion tank — Figure 4 1. Ensure expansion tank size will handle boiler and system water v olume and temperature. T ank must be located in boiler return piping as close to boiler as possible, before inlet side o[...]

  • Page 16

    P art number 550-110-260/0200 16 GOLD CGs Gas-F ired Water Boiler W ater 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 design allows changing boiler flow rate without[...]

  • Page 17

    P art number 550-110-260/0200 17 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 circulator 5 Zone valve 6 Drain valve 9 R[...]

  • Page 18

    P art number 550-110-260/0200 18 GOLD CGs Gas-F ired 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. 3. Gradually open valve 7a while closing valve 7[...]

  • Page 19

    P art number 550-110-260/0200 19 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 temperature valves (see instructions to the left for adju[...]

  • Page 20

    P art number 550-110-260/0200 20 GOLD CGs Gas-F ired Water Boiler W ater piping — low temp systems 3e This piping method is called a boiler -bypass because part of the circulator flo w is bypassed around the boiler (through valve 7a ). This method reduces the flow rate throughout the boiler , in or der to raise the average wate r temperature in t[...]

  • Page 21

    P art number 550-110-260/0200 21 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 left for adjusting valves) 8 Blend temperature gauge 9 Relief valve 10 A utomatic air v ent (with diaphrag m-t[...]

  • Page 22

    P art number 550-110-260/0200 22 GOLD CGs Gas-F ired Water Boiler W ater 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. V alv e 7a regulates the amount of boiler supply wat er mixed with r[...]

  • Page 23

    P art number 550-110-260/0200 23 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 A utomatic air ve nt (with diap hragm-t ype expansion tank), or connect to tank fitting (closed-type expansion tank). DO NOT use an aut omatic air vent[...]

  • Page 24

    P art number 550-110-260/0200 24 GOLD CGs Gas-F ired Water Boiler Gas piping 5 Connecting gas supply piping to boiler Figure 14 Gas supply piping V enting and combustion air 4 CGs Boiler must be vented and supplied with combustion and ventilation air as described in W eil-McLain CGs V enting Supplements pa cked in en velope assembly with boiler . F[...]

  • Page 25

    P art number 550-110-260/0200 25 Boiler Manual T able 4 Pipe capacity for 0.60 specific gravity natural gas Gas piping continued 5 Natural Gas: 1. Refer t o T able 4 for pipe length and diamete r . Base on rated boiler input (divide by 1,000 to obtain cubic feet per hour). T able 4 is only for gas with specific gravity 0.60, with a pressure drop th[...]

  • Page 26

    P art number 550-110-260/0200 26 GOLD CGs Gas-F ired Water Boiler Figure 15 Field wiring connections — service switch and thermostat (or end switch) provided by installer Fo r your safety , tur n of f electrical power supply at service entrance panel befor e making an y electrical connections to avoid possible electric shock hazard. Failure to do[...]

  • Page 27

    P art number 550-110-260/0200 27 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 o ccur , res ulting in substant ial pro per ty damage. Eliminate all system leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up i[...]

  • Page 28

    P art number 550-110-260/0200 28 GOLD CGs Gas-F ired Water Boiler 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 . R epeat this inspection after the boiler has been started and the system has heated up. Leak[...]

  • Page 29

    P art number 550-110-260/0200 29 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 T ypical pilot burner flame Figure 17 T ypical main burner flame Check burner flames View pilot and main flames through the inspection port in the Air inlet [...]

  • Page 30

    P art number 550-110-260/0200 30 GOLD CGs Gas-F ired Water Boiler Check - out procedure — checklist 8 ❏ Boiler and heat distribution units filled with water? ❏ A utomatic air v ent, if used, open one full turn? ❏ Air purged from system? ❏ Air purged from gas piping? Piping checked for leaks? ❏ Correctly sized manifold orifices installed[...]

  • Page 31

    P art number 550-110-260/0200 31 Boiler Manual Operation — sequence 9a Figure 18 Control module sequence of operation — status light indications 1. Read Lighting instr uctions on page 34. T his information is also located on a label on the inside of the boiler jacket door panel. 2. Raise room thermostat to call for heat. 3. Inducer and circulat[...]

  • Page 32

    P art number 550-110-260/0200 32 GOLD CGs Gas-F ired Water Boiler Operation — wiring diagrams 9b Figure 19 Schematic wiring diagram[...]

  • Page 33

    P art number 550-110-260/0200 33 Boiler Manual Figure 20 Ladder wiring diagram 71033 1. All w iring must be installed in accor dance with: A. U .S.A. — N.E.C. And an y other national, stat e, or local code requir ements. B. Canada — C.S.A. C22.1 C.E.C. Part 1 and any other national, pr ovincial, or local c ode require- ments. 2. Pilot lead w ir[...]

  • Page 34

    P art number 550-110-260/0200 34 GOLD CGs Gas-F ired Water Boiler Operation — lighting instructions 9c Figure 21 Lighting instructions FOR YOUR SAFETY READ BEFORE OPERA TING OPERA TING INSTRUCTIONS TO TURN OFF GAS TO THE APPLIANCE • Do not try to light any appliance. • Do not touch any electric switch; do not use any phone in your building. ?[...]

  • Page 35

    P art number 550-110-260/0200 35 Boiler Manual T able 5 Service and maintenance schedules Service and maintenance — schedule 10a Follow the Service and maintenance procedures given throughout this manual and in compon ent literature shipped with the boiler . Failur e to perform the service and maintenance could result in damage to the boiler or s[...]

  • Page 36

    P art number 550-110-260/0200 36 GOLD CGs Gas-F ired Water Boiler Service & maintenance — annual start -up 10b The boiler should be inspected and star ted annually , at the beginning of the heating season, only b y a qualified service te chnician . In addition, the maintenance and care o f the boiler designated in T able 5 and explained on th[...]

  • Page 37

    P art number 550-110-260/0200 37 Boiler Manual ❏ Service . . . . . . . . . . ❏ Inspect . . . . . . . . . . Inducer motor 1. W ith boiler power OFF , plac e a few drops o f S.A.E. 20 motor oil in each of the two oil cups. Use on ly S.A.E. 20 motor oil to lubricate the induc er motor . Do not use universal household oils. Motor could be damaged, [...]

  • Page 38

    P art number 550-110-260/0200 38 GOLD CGs Gas-F ired Water Boiler Service & maint. — annual start -up continued 10b ❏ Start-up . . . . . . . . . 1 . Start the b oiler , follo w ing the instruct ions in manual section 7 . 2. V erify cold fill pressur e is correct and that fill system is w orking properly . 3. V erify antifreez e level (if us[...]

  • Page 39

    P art number 550-110-260/0200 39 Boiler Manual circulation of air-saturated tank water back to the system and prevents the air from bubbling up through the water as it returns from the system. • Do not use automatic air vents in systems with closed-type tanks. The air will escape from the system instead of returning to the tank. E ve ntually , th[...]

  • Page 40

    P art number 550-110-260/0200 40 GOLD CGs Gas-F ired Water Boiler 1. Review the User’ s Infor mation Manual with the owner . 2. Emphasize the need to perf orm the maintenance schedule specified in the User’ s Infor mation Manual (and in this manual as well). 3. Remind the owner of the need to call in a licensed contractor should the boiler or s[...]

  • Page 41

    P art number 550-110-260/0200 41 Boiler Manual T roubleshooting — procedure 11a Label all wires prior to disconnection when se r vicing controls. Wiring errors can cause improper and dangerous operation. Never jumper (bypass) rollout thermal fuse element or any other device ex cept for momentar y testing as outlined in T roubleshooting Char ts . [...]

  • Page 42

    P art number 550-110-260/0200 42 GOLD CGs Gas-F ired Water Boiler T roubleshooting — air pressure switch 11b Make sure boiler water temperature is 100 °F or cooler before starting procedure to obtain appropriate readings. Check pressure switch setting 1. See Figur e 24 and T able 6 . 2. Remove both air pressure switch hoses from air pressure swi[...]

  • Page 43

    P art number 550-110-260/0200 43 Boiler Manual T roubleshooting — control module 11c 26036 Make sure ground wir ing is installed per wiring diagram. Good grounding is extremely important for proper operation. Control indicator lights — non-lockout modes FLAME light flashing alone U sually indicates pilot flame was not established within 15 seco[...]

  • Page 44

    P art number 550-110-260/0200 44 GOLD CGs Gas-F ired Water Boiler T roubleshooting — control module continued 11c Figure 25 Control module connections Indicator lights POWER TST A T CIRC LIMIT PRESS SWIT CH FLAME 120 V AC IN 120 V AC to transformer High voltage to spark electrode 24 V AC from transformer 24 V AC control circuits 120 V AC to circu[...]

  • Page 45

    P art number 550-110-260/0200 45 Boiler Manual T roubleshooting — control module lights 11d CHART 1 — Troubleshootin g POWER light status Electrical shock h azard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions. Fai lure to follow instructions could result in severe personal injury, death or substantial pro perty damage. P[...]

  • Page 46

    P art number 550-110-260/0200 46 GOLD CGs Gas-F ired Water Boiler T roubleshooting — control module lights 11d Electrical shock hazard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions. Failure to fo llow instructions could result in severe personal injury, death or substantial pro perty damage. CHART 2 — TSTAT CIRC & PO[...]

  • Page 47

    P art number 550-110-260/0200 47 Boiler Manual continued CHART 3 — PRESS SWITCH & POWER lights flashing Electrical shock hazard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions. Failure to fo llow instructions could result in severe personal injury, death or substantial pro perty damage. • Boiler should be in normal ope[...]

  • Page 48

    P art number 550-110-260/0200 48 GOLD CGs Gas-F ired Water Boiler T roubleshooting — control module lights 11d • Turn off power to the boiler at service switch or breake r. • Wait at least 45 seconds. • Turn on power to boiler. • Restart boiler, following Lighting instructions in this manual ( Figure 21 , page 34). • Look through the pi[...]

  • Page 49

    P art number 550-110-260/0200 49 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 gas valve: Natural gas — 5.0" w.c. min/14.0" w.c. max Propane — 11.0" w.c. min/14.0" w.c. max Is [...]

  • Page 50

    P art number 550-110-260/0200 50 GOLD CGs Gas-F ired Water Boiler T roubleshooting — 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 fo llow instructions could result in severe personal injury, deat[...]

  • Page 51

    P art number 550-110-260/0200 51 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 fo llow instructions could result in severe personal injury, death or substantial pro perty damage. • Replace[...]

  • Page 52

    P art number 550-110-260/0200 52 GOLD CGs Gas-F ired Water Boiler Replacement parts 12a Section assembly ................................................ 53 Base assembly .................................................... 54 Jack et assembly ................................................. 55 T rim assembly ......................................[...]

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  • Page 58

    P art number 550-110-260/0200 58 GOLD CGs Gas-F ired Water Boiler Dimensions 13a Figure 31 Dimensional drawing T OP VIE W 19 19 13¹¹₁₆ 28³⁄₈ 1⁵⁄₈ 4³⁄₄ 4³⁄₄ 13¹⁄₄ 11¹⁄₈ NO TE 2 NO TE 2 2³⁄₈ 2¹⁄₄ 3¹⁄₄ W A 9 12 23¹⁄₄ MODEL CGi Pressure/temperature g auge Supply piping ( ) note 1 Return piping[...]

  • Page 59

    P art number 550-110-260/0200 59 Boiler Manual Ratings T able 7 Boiler ratings DOE 1 . A dd “PIN” for natural gas boiler - “PIL ” f or propane gas boiler . 2. Based on standard test procedures prescribed by the U nited States Department of Energy . 3. Net I=B=R ratings are based on net installed radiation of sufficient quantity for the requ[...]

  • Page 60

    60 P art Number 550-110-260/0200 GOLD CGs Gas-F ired Water Boiler — Boiler Man ual W eil-McLain 500 Blaine Street Michigan City , IN 46360-2388 http://www .weil-mclain.com Handling ceramic fiber and fiberglass materials REMO V AL OF COMBUSTION CHAMBER LINING OR BASE P ANELS The combustion chamber lining or base insulation panels in this product c[...]