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Weil-McLain 550-110-260/0508 manual

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Table of contents for the manual

  • Page 1

    P ar t No . 550-110-260/0508 This manual must only be used by a qualifi ed heating installer/serv ice tec hnician. Bef ore installing , read all instructions, including this manual, the burner manual and any relat ed supplements. P erform steps in the order given. Failure to c omply could result in seve re personal injur y , death or substantial p[...]

  • Page 2

    Part number 550-110-260/0508 2 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual How it works . . . ① Control module The control module r esponds to signals from the room thermostat, air pressure switch and boiler limit circuit to operate the boiler cir culator , pilot burner , gas val ve and inducer . When room thermostat calls for heat, the co[...]

  • Page 3

    Part number 550-110-260/0508 3 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual GOLD CGs Gas-Fir ed Induced-Draft W ater Boiler[...]

  • Page 4

    Part number 550-110-260/0508 4 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Contents Hazar d defi nitions The following defi ned terms are used throughout this manual t o bring attention to the presence of hazards of various risk le v els or to important infor mation co ncerning the life of the product. Indicates pr esence of hazards that w[...]

  • Page 5

    Part number 550-110-260/0508 5 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Please r ead befor e pr oceeding Installer Read all instr uctions befor e in- stalling. Follo w all instructions in proper order to pr event personal injur y or death. • Also r efer to CGs V enting Supplements . • Consider piping and installation when determining [...]

  • Page 6

    Part number 550-110-260/0508 6 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Prepare boiler location — codes & checklist 1a Installations must follow these codes: • Local, state, provincial, and national codes, laws, regulations and ordinanc es. • N ational Fuel Gas Code, ANSI Z223.1–latest edition. • Standard for C ontrols and S[...]

  • Page 7

    Part number 550-110-260/0508 7 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler location — clearances 1b Figure 2 Required MINIMUM clearances Figure 1 Recommended SER VICE clearances (see W ARNING below) Recommended SERVICE clearances (Fig. 1) 1. Pro v ide clearances for cleaning and servicing the boiler and for access t o cont[...]

  • Page 8

    Part number 550-110-260/0508 8 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler location — vent system 1c F ailure to follo w all instr uctions can result in fl ue gas spillage and carbon mono xide emissions, causing sev ere personal injur y or death. When r emoving boiler from an existing common vent system: At the time of re[...]

  • Page 9

    Part number 550-110-260/0508 9 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler location — contamination 1d T able 1 Corrosive or destructive contaminants and likely locations T o prevent potential of severe personal injur y or death, check for products or ar eas listed below befor e installing boiler . If any of these contamin[...]

  • Page 10

    Part number 550-110-260/0508 10 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler location — air openings 1e Special considerations Tight construction ANSI Z223.1 defines unusually tight construction where: 1. W alls and ceilings exposed to the outside atmo- sphere ha ve a contin uous water vapor retarder with a rating of 1 perm[...]

  • Page 11

    Part number 550-110-260/0508 11 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Figure 3 Sizing air openings for CGs installations ✷[...]

  • Page 12

    Part number 550-110-260/0508 12 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Place boiler/crate near position 1. Leav e boiler in crate and on pallet until installation site is read y . 2. M ove entir e crate and pallet next to selected loca- tion. 3. Remo ve crate. 4. R emove boiler fr om pallet. Do not drop boiler or bump jack et on fl oor[...]

  • Page 13

    Part number 550-110-260/0508 13 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler — pr essure test 2b Hydr ostatic pressur e test Pr essure test boiler bef or e attaching water or gas piping (ex cept as noted belo w) or electr ical supply . Prepar e boiler for test 1. R emove the shipping nipple (from CGs supply tap- ping) and r[...]

  • Page 14

    Part number 550-110-260/0508 14 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual W ater piping — general information 3a T able 3 W ater pipe size (based on 20°F rise) General piping information If installation is to comply with ASME or Canadian requir ements, an ad- ditional high temperat ure limit is needed. Install contr ol in supply piping [...]

  • Page 15

    Part number 550-110-260/0508 15 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Water piping — single-zone system 3b Figure 4 Diaphragm- or bladder -type expansion tank Piping to single-zone system See T able 3 for piping sizes. Figure 5 Closed-type expansion tank Piping to single-zone system See T able 3 for piping sizes. Diaphragm-type or bl[...]

  • Page 16

    Part number 550-110-260/0508 16 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual W ater piping — multiple zones 3c Piping multiple zones Follo w instructions on pages 14 and 15 to install near- boiler or single-zone piping. (Also r efer to Piping for radiant heating syst ems or conv ert ed gravity sys- tems , below , if applicable.) See Figure [...]

  • Page 17

    Part number 550-110-260/0508 17 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual 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) valv es 2 Flow/check valv e 3 System or zone circulat or 5 Zone valve 6 Drain valv e 9 Relief valv[...]

  • Page 18

    Part number 550-110-260/0508 18 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Piping — low temp systems 3d Failure to prevent low return water temperature t o the boiler c ould cause corrosion of the boiler sections or burners, r esulting in severe personal injury , death or substantial property damage. Radiant heating system piping should i[...]

  • Page 19

    Part number 550-110-260/0508 19 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual 1 Boiler isolation (balancing) valves 2 Flow/check valv e 3 System or zone circulat or 4 Syst em temperature gauges 5 Zone valve 6 Drain valv e 7 Syst em temperature valv es (see instruc- tions to the left for adjusting valv es) 8 Blend temperature gauge 9 Relief val[...]

  • Page 20

    Part number 550-110-260/0508 20 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Failure to prevent low return water temperature t o the boiler c ould cause corrosion of the boiler sections or burners, r esulting in severe personal injury , death or substantial property damage. Radiant heating system piping should include a means of regulating th[...]

  • Page 21

    Part number 550-110-260/0508 21 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual 1 Boiler isolation (balancing) valves 2 Flow/check valv e 3 System or zone circulat or 4 Syst em temperature gauges 5 Zone valve 6 Drain valv e 7 S ystem temperature val ves (see instructions to the left for adjusting valv es) 8 Blend temperature gauge 9 Relief valve[...]

  • Page 22

    Part number 550-110-260/0508 22 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Failure to prevent low return water temperature t o the boiler c ould cause corrosion of the boiler sections or burners, r esulting in severe personal injury , death or substantial property damage. Radiant heating system piping should include a means of regulating th[...]

  • Page 23

    Part number 550-110-260/0508 23 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual 3 System or z one circulator 7 System t emperature valves (see instructions to the left for adjusting valv es) 8 Blend temperature gauge 9 Relief valv e 10 A utomatic air vent (with diaphragm-t ype expan- sion tank), or connect to tank fi tting (closed-t ype expansi[...]

  • Page 24

    Part number 550-110-260/0508 24 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Venting and combustion air 4 CGs Boiler must be vented and supplied with combus- tion and ventilation air as described in W eil-McLain CGs V enting Supplements packed in env elope as- sembly with boiler . Failure to do so will cause sever e personal injur y or death.[...]

  • Page 25

    Part number 550-110-260/0508 25 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Gas piping 5 26020 Manual main shutof f gas valve (when required) Ground joint union (when required) Nipple Te e Cap T able 4 Pipe capacity for 0.60 specifi c gravity natural gas Natural Gas: 1. Refer t o T able 4 for pipe length and diameter . Base on rated boiler [...]

  • Page 26

    Part number 550-110-260/0508 26 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Field wiring 6 Thermostat 1. Connect thermostat as shown on wir ing diagram on boiler . 2. Install on inside wall away from in fl uences of draf ts, hot or cold wat er pipes, lighting fi xtur es, television, sunra ys, or fi replaces. 3. If thermostat has a heat an[...]

  • Page 27

    Part number 550-110-260/0508 27 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Start-up — pr eparation 7a Fill the system with water 1. Close manual and aut omatic air vents and boiler drain cock. 2. Fill to correct system pressure . Co r- rect pressur e will var y with each application. T ypical cold water fi ll pressure for a residential s[...]

  • Page 28

    Part number 550-110-260/0508 28 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Start-up — operate boiler 7b Inspect system water piping After fi lling the boiler and system with water , inspect all piping throughout the system for leaks. If found, repair immediately . Repeat this inspection aft er the boiler has been started and the system h[...]

  • Page 29

    Part number 550-110-260/0508 29 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Start-up — operate boiler (continued) 7b Figure 16 T ypical pilot bur ner fl ame Figure 17 T ypical main bur ner fl ame Check bur ner fl ames V iew pilot and main fl ames through the inspection port in the A ir inlet box fr ont cov er . Pilot burner fl ame ( F[...]

  • Page 30

    Part number 550-110-260/0508 30 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Check-out pr ocedur e — checklist 8 ❏ Boiler and heat distribution units fi lled with water? ❏ A utomatic air vent, if used, open one full turn? ❏ Air purged from syst em? ❏ Air purged from gas piping? Piping c hecked for leaks? ❏ Correctly sized manifol[...]

  • Page 31

    Part number 550-110-260/0508 31 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Operation — sequence 9a Figure 18 Control module sequence of operation — status light indications 1. Read appr opr iate Operating instr uctions in Section 9c . This information is also located on a label on the inside of the boiler jack et door panel. 2. Raise ro[...]

  • Page 32

    Part number 550-110-260/0508 32 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Operation — wiring diagrams 9b Figure 19 Schematic wiring diagram[...]

  • Page 33

    Part number 550-110-260/0508 33 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Figure 20 Ladder wiring diagram[...]

  • Page 34

    Part number 550-110-260/0508 34 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual 9c Operating instructions CGs-3 to CGs-6 • Spark pilot • Natural or propane gas • Gas valve: Honeywell VR8204/VR8304[...]

  • Page 35

    Part number 550-110-260/0508 35 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Operating instructions CGs-3 to CGs-6 • Spark pilot • Natural or propane gas • Gas valve: White-Rodg ers 36E 9c[...]

  • Page 36

    Part number 550-110-260/0508 36 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual 9c Operating instructions CGs-3 to CGi-6 • Spark pilot • Natural or propane gas • Gas valve: White-Rodg ers 36C[...]

  • Page 37

    Part number 550-110-260/0508 37 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual T able 5 Service and maintenance schedules Service and maintenance — schedule 10a Service technician (see following pages for instructions) Owner maintenance (see CGs User’s Information Manual for instructions) A NNNUAL S TART - UP In sp ect: • Reported problem[...]

  • Page 38

    Part number 550-110-260/0508 38 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Service & maintenance — annual start-up 10b Air openings 1. V erify that combustion and ventilation air openings to the boiler room and/or building ar e open and unobstr ucted . 2. V erify that boiler vent discharge is clean and fr ee of obstr uctions . Flue ga[...]

  • Page 39

    Part number 550-110-260/0508 39 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual ❏ Inspect . . . Burners, base and inlet air box The boiler contains c eramic fi ber and fi berglass materials. U se care when handling these materials per instructions on page 68 of this manual. Failure to co mply could result in sever e personal injur y . If ins[...]

  • Page 40

    Part number 550-110-260/0508 40 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Service & maint. — annual start-up continued 10b ❏ Check/test . . . Gas piping 1. Sniff near fl oor and around boiler area for an y in- dication of a gas leak . 2. T est gas piping using bubble test, per Section 5 of this manual, if there is an y indication [...]

  • Page 41

    Part number 550-110-260/0508 41 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Safety relief valv es should be reinspected A T LEAST ONCE EVER Y THREE YEARS , by a licensed plumbing c ontr actor or authorized inspection agency , to ensure that the pr oduct has not been affected by corrosi ve water conditions and t o ensure that the valve and di[...]

  • Page 42

    Part number 550-110-260/0508 42 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Service & maint. — annual start-up 10b ❏ Review with owner 1. Review the User’ s Information Manual with the ow ner. 2. Emphasize the need to perform the maintenance schedule specified in the User’ s Information Manual (and in this manual as well). 3. Re [...]

  • Page 43

    Part number 550-110-260/0508 43 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — pr ocedur e 11a Label all wires prior to disconnection when serv icing co ntrols. W ir ing errors can cause improper and danger ous operation. Never jumper (b y pass) r ollout thermal fuse element or any other device exc ept for momentar y testi[...]

  • Page 44

    Part number 550-110-260/0508 44 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — air pr essur e switch 11b Air pr essure switch Mak e sure boiler water t emperature is 100 °F or cooler before starting procedur e to obtain appropriate readings. Check pressur e switch setting 1. See Figure 24 and T able 6 . 2. Remo ve both ai[...]

  • Page 45

    Part number 550-110-260/0508 45 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — contr ol module 11c Contr ol module Solder or wat er splatter between plugs and circuit boar d can cause improper operation of control module. Place a shield ov er the boiler internal controls and c omponents during installation. F ailure to co [...]

  • Page 46

    Part number 550-110-260/0508 46 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — contr ol module (continued) 11c Figure 25 Control module connections[...]

  • Page 47

    Part number 550-110-260/0508 47 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — contr ol module lights 11d CHART 1 — Troubleshooting POWER light status Electrical shock haza rd — Wherever you se e ▲ TURN OFF POWER ▲ , follow the instructions. Failur e to follow instructions could result in severe personal injury, de[...]

  • Page 48

    Part number 550-110-260/0508 48 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — contr ol module lights 11d Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions. Failure to follow instructions could result in severe personal inju ry, death or substantial property damage. CHART 2 — TSTAT CIR[...]

  • Page 49

    Part number 550-110-260/0508 49 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — contr ol module lights (cont.) 11d CHART 3 — PRESS SWITCH & POWER lights flashing Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instruction s. Failure to follow instructions could result in severe personal inju r[...]

  • Page 50

    Part number 550-110-260/0508 50 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual 11d T r oubleshooting — contr ol 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 in structions in this manual (page 34, 35 or 36)[...]

  • Page 51

    Part number 550-110-260/0508 51 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — contr ol 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: Natural gas — 5.0" w.[...]

  • Page 52

    Part number 550-110-260/0508 52 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual 11d T r oubleshooting — contr ol 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 instruction s. Failure to follow instructions could result in severe pe[...]

  • Page 53

    Part number 550-110-260/0508 53 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — contr ol 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 to follow instructions could result in [...]

  • Page 54

    Part number 550-110-260/0508 54 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Replacement parts 12a Section assembly .............................................. 55 Base .................................................................. 56 Jacket ............................................................... 58 T rim .......................[...]

  • Page 55

    Part number 550-110-260/0508 55 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Replacement parts — section assembly 12b Item number Description Weil-McLain part number 1 End section, left hand, 51124 311-103-830 2 End section, right hand 51128 311-103-821 3 Intermediate section, 51125 311-103-818 not shown Replacement section assembly CGs-3 C[...]

  • Page 56

    [...]

  • Page 57

    Part number 550-110-260/0508 57 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Replacement parts — base (continued) 12c I t em De sc rip t ion Weil-M c L a in p a r t number B a se i nsul a t i on k i t ( i n c ludes i nsul a t i on f or a ll b a se p a rts a bove plus g a sket m a ter ia l needed between blo c k a ssembly a nd b a se) CGs-3 [...]

  • Page 58

    Part number 550-110-260/0508 58 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Replacement parts — jacket 12d Figure 28 Jacket assembly[...]

  • Page 59

    Part number 550-110-260/0508 59 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Boiler Model 1 2 3 4 5 6 Boiler Model Junction box, 2 x 4 Panel, left side , with insu lation Panel, right side , with insulation Panel , top front , with insul ation Panel, top rea r , with insulation Panel, door Natural Gas Propane Gas W eil-McLain pa rt numb er CG[...]

  • Page 60

    Part number 550-110-260/0508 60 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Replacement parts — trim 12e Figure 29 T rim assembly I t em number De sc rip t ion M a nuf act urer M a nuf act urer ’ s p a r t number Weil-M c L a in p a r t number 1 Pressur e relief valve, ASME, 30 PSIG, ¾" male inlet Pressur e relief valve, ASME, 30 P[...]

  • Page 61

    Part number 550-110-260/0508 61 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Replacement parts — contr ols 12f Figure 30 Gas control assembly I t em number De sc rip t ion M a nuf act urer M a nuf act urer’ s p a r t number Weil-M c L a in p a r t number N at ur a l g as c omponen ts 1 G a s v a lve, ½" x ½", CGs-3 through CGs[...]

  • Page 62

    Part number 550-110-260/0508 62 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Dimensions 13a Figure 31 Dimensional drawing Boiler model number Supply tappin g (inches NPT) Return tappin g (inches NPT) Gas connection size Note 3 (inches NPT) Gas mani f old size Note 3 (inches NPT) “A” Air inlet pipe center (inches) “W” Jacket width (inc[...]

  • Page 63

    Part number 550-110-260/0508 63 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Ratings T able 7 Boiler ratings DOE 13b (N ote 5) CGs boilers for residential radiant panel systems, con ver ted gravit y heating systems or other lo w water tempera- ture applications should be installed with balancing valves and b y pass piping equal to the supply [...]

  • Page 64

    64 Part Number 550-110-260/0508 GOLD CGs Gas-F ired Water Boiler — Boiler Man ual Handling ceramic fi ber and fi ber glass materials REMOV AL OF COMBUSTION CHAMBER LINING OR BASE P ANELS The combustion chamber lining or base insulation panels in this prod- uct contain c eramic fi ber materials. Ceramic fibers can be con verted to cristobalite [...]