Weil-McLain GOLD CGS 550-110-260/02002 User Manual
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Weil-McLain GOLD CGS 550-110-260/02002 User Manual

Weil-McLain GOLD CGS 550-110-260/02002 User Manual

Gas-fired water boiler
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Summary of Contents for Weil-McLain GOLD CGS 550-110-260/02002

  • Page 2: How It Works

    GOLD 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 room thermostat calls for heat, the control module starts the system circulator and inducer. The control module runs the inducer long enough to purge the boiler flue passages, then opens the pilot valve and activates pilot ignition spark.

  • Page 4: Table Of Contents

    GOLD Contents How it works ... 2–3 Hazard definitions... 4 Please read before proceeding ... 5 1. Prepare boiler location ... 6–11 2. Prepare boiler ... 12–13 3. Water piping... 14–23 4. Venting & combustion air ... 24 5. Gas piping ... 24–25 6.

  • Page 5: Please Read Before Proceeding

    Boiler Manual Please read before proceeding Installer Read all instructions before installing. proper order to prevent personal injury or death. • Also refer to CGs • Consider piping and installation determining boiler location. • claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

  • Page 6: Prepare Boiler Location

    GOLD Prepare boiler location — Installations must follow these codes: Before locating the boiler, check the following: Gas-Fired Water Boiler • Local, state, provincial, and national codes, laws, regulations and ordinances. • National Fuel Gas Code, ANSI Z223.1 – latest edition. •...

  • Page 7: Flooring And Foundation

    Boiler Manual Prepare boiler location — Provide the following clearances: 1. Hot water pipes — at least ½" from combustible materials. 2. Recommended service clearances — See 3. Minimum clearances for tight spaces — See Figure 2 Figure 1 Recommended clearances for service Figure 2 Minimum clearances for tight spaces Part number 550-110-260/0200 clearances...

  • Page 8: Vent System

    GOLD Prepare boiler location — Removing from existing vent Do not install the CGs into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death or substantial property damage.
  • Page 9 Boiler Manual Prepare boiler location — Air contamination Please review the following information on potential combustion air contamination problems. If the boiler is installed in would contaminate the air cannot be removed, you must air intake. Contaminated combustion air will damage the boiler, resulting in possible severe personal injury, death or substantial property damage.

  • Page 10: Air Openings

    GOLD Prepare boiler location — CGs combustion air options Using inside air — direct exhaust vent The CGs boiler can use inside air if no contaminants are present in the boiler space. If contaminants are likely to be present, install the CGs boiler as a direct vent appliance, using the appropriate vent supplement and the instructions in this manual.
  • Page 11 Boiler Manual Figure 3 Sizing air openings for CGs installations Room Air Openings Required area of the air openings given in this table are free area — after the correction for louver obstruction. (See Exception below.) Apply this table only to installations with clearances no smaller than those shown in Figure 1, page 7 of this manual.

  • Page 12: Prepare Boiler

    Table 2 Manifold orifice sizing Location U. S. Canada Note 1: For elevations above 2,000 feet, contact your local Weil-McLain sales office for details. Gas-Fired Water Boiler placement & setup 3. Reinstall inlet air box top panel. Orifice replacement procedure (when required) 1.

  • Page 13: Prepare Boiler

    Boiler Manual Prepare boiler — Perform hydrostatic pressure test Pressure test boiler supply. Prepare boiler for test 1. Remove the shipping nipple (from CGs supply tapping) and remove the boiler relief 2. Remove 1¼" nipple, reducing tee and drain valve from accessory bag. Install in boiler 3.

  • Page 14: Water Piping

    GOLD Water piping — General piping information If installation is to comply with ASME or Canadian requirements, an additional is needed. Install control in supply high temperature limit piping between boiler and isolation valve. Set second control to minimum 20 °F above setpoint of first control. Maximum allowable setpoint is 240 °F. See section , page 32 for wiring.

  • Page 15: Expansion Tank

    Boiler Manual Water piping — Expansion tank Diaphragm-type or bladder-type expansion tank — Figure 4 1. Ensure expansion tank size will handle boiler and system water volume and temperature. Tank must be located in boiler return piping as close to boiler as possible, before inlet side of circulator.
  • Page 16 130 °F regardless of system supply temperature. Contact your Weil-McLain representative for suggested piping and control methods. Failure to prevent cold return water temperature to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.
  • Page 17 Boiler Manual typical piping — multiple-zone installations Figure 6 Zoning with circulators — return water 130 °F or higher. ZONE 2 ZONE 1 Cold water fill 26012 Boiler isolation (balancing) valves Flow/check valve System or zone circulator Zone valve Drain valve Relief valve Automatic air vent (with diaphragm-type expansion tank), or connect to tank fitting (closed-...

  • Page 18: Temperature Gauges

    DO NOT reset control water temperature at no less than 130 °F your Weil-McLain representative for suggested piping and control methods. Failure to damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.
  • Page 19 Boiler Manual primary/secondary (preferred) bypass piping — for radiant heating or converted gravity systems Figure 8 Zoning with circulators ZONE 2 ZONE 1 12" MAX. Alternate circulator location Cold water fill 26014 Boiler isolation (balancing) valves Flow/check valve System or zone circulator System temperature gauges Zone valve Drain valve...
  • Page 20 DO NOT reset control water temperature your Weil-McLain representative for suggested piping and control methods. Failure to damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage. Gas-Fired Water Boiler...
  • Page 21 Boiler Manual boiler-bypass (alternate) piping — for radiant heating or converted gravity systems Figure 10 Boiler-bypass piping Zoning with circulators (Alternative to primary/secondary piping Figures 8 and 9) ZONE 2 ZONE 1 Cold water fill 26016 Boiler isolation (balancing) valves Flow/check valve System or zone circulator System temperature gauges...
  • Page 22 DO NOT reset control water temperature your Weil-McLain representative for suggested piping and control methods. Failure to damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage. Gas-Fired Water Boiler...

  • Page 23: Water Piping

    Boiler Manual system-bypass (alternate) piping — for converted gravity (or steam) systems From system Cold water fill 26018 Water piping — Figure 13 Piping refrigeration systems System supply Circulator System return 26019 Part number 550-110-260/0200 To system Figure 12 System-bypass piping Zoning with zone valve or circulators, return water 130 °F or higher.

  • Page 24: Venting & Combustion Air

    Gas-Fired Water Boiler CGs Boiler must be combustion and ventilation air V enting Weil-McLain CGs envelope assembly with boiler. Failure to do so will cause severe personal injury or death. air quality cannot be assured to be free of regarding contaminants contaminants and locations likely to contain them.

  • Page 25: Gas Piping

    Boiler Manual Gas piping Support piping accessories. from gas supply piping. Purge all air 4. Before placing boiler in operation, and its gas connection for leaks. Close manual main shutoff pressure testing at less than 13" w.c. Disconnect boiler and gas valve from gas supply piping greater than 13"...

  • Page 26: Field Wiring

    GOLD Field wiring For your safety, power supply at service entrance panel before making any electrical connections electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring must be N.E.C. Class 1. If original wiring as supplied with boiler must be replaced, use only type Boiler must be...

  • Page 27: Start-Up

    Boiler Manual Start-up — Determine if water treatment is needed Do not use petroleum-based cleaning or sealing in boiler system. Severe damage to boiler compounds will occur, resulting in substantial property damage. Eliminate all system leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating cast iron, and causing section failure.

  • Page 28: Start The Boiler

    GOLD Start-up — Inspect system water piping After filling the boiler and system with water, throughout the system for leaks. If found, repair immediately. Repeat this inspection after the boiler has been started and the system has heated up. Leaks must be repaired at once. Failure to do so can damage the boiler, resulting in substantial property damage.

  • Page 29: Start-Up

    Boiler Manual Start-up — Check around the boiler the procedure of section If you discover evidence of any gas leak, shut down the boiler at once. Find the leak source with bubble test and repair immediately. Do not start boiler again until corrected.

  • Page 30: Check-Out Procedure

    GOLD Check-out procedure — ❏ 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 sized manifold orifices installed? Refer to manual section to check size and fuel type.

  • Page 31: Operation

    Boiler Manual Operation — Read Lighting instructions information is also located on a label on the inside of the boiler jacket door panel. room thermostat to call for heat. Raise Inducer and circulator energize. switch proves proper airflow, control module initiates 30-second prepurge.
  • Page 32 GOLD Operation — Figure 19 Schematic wiring diagram Gas-Fired Water Boiler wiring diagrams Part number 550-110-260/0200...
  • Page 33 Boiler Manual Figure 20 Ladder wiring diagram Electrical shock hazard — can cause severe injury or death. Disconnect power before installing or servicing. All contacts are shown without power applied. Legend for ladder wiring diagram 120 VAC field wiring Low voltage field wiring 120 VAC factory wiring Low voltage factory wiring High voltage spark ignition wiring...

  • Page 34: Operation

    GOLD Operation — Figure 21 Lighting instructions FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner.

  • Page 35: Service And Maintenance

    Boiler Manual Service and maintenance — Table 5 Service and maintenance schedules Service technician (see following pages for instructions) Inspect: • Reported problems • Boiler area • Air openings • Flue gas vent system (and air piping) • Pilot and main burner flames •...
  • Page 36 GOLD Service & maintenance — The boiler should be service technician the following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could result in equipment failure. ❏ Inspect ..Reported problems Inspect any problems reported by owner and correct before proceeding.

  • Page 37: Condensate Drain System

    Boiler Manual ❏ Inspect ..Eliminate all system or boiler leaks. makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating cast iron, and causing section failure. Leaking water may also cause severe property damage.
  • Page 38 GOLD Service & maint. — ❏ Start-up ..1. Start the boiler, following the instructions in manual section 2. Verify cold fill pressure system is working properly. 3. Verify antifreeze level concentration and that inhibitor level is correct. ❏...
  • Page 39 Boiler Manual ❏ Check/test ..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.

  • Page 40: Review With Owner

    GOLD Service & maint. — ❏ Review with owner ..1. Review the 2. Emphasize the need to perform the maintenance schedule specified in the 3. Remind the owner of the need to call in a licensed contractor should the boiler or system 4.

  • Page 41: Troubleshooting

    Boiler Manual Troubleshooting — Before troubleshooting: Check the following: VERIFY PROPER OPERATION AFTER SERVICING. Part number 550-110-260/0200 procedure 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 device except for momentary testing as outlined in personal injury, death or substantial property damage can result.

  • Page 42: Air Pressure Switch

    Pressure White Flue collector White Rear panel Interior panel 26035 Table 6 Pressure switch setpoint (for elevations above 2,000 ft, contact your local Weil-McLain sales office for details.) Boiler model number Inches W.C. CGs-3 1.79" CGs-4 1.48" CGs-5 1.22" CGs-6 0.95"...
  • Page 43 Boiler Manual Troubleshooting — Control indicator lights — lockout modes through Charts 1 troubleshooting procedures. To reset control after a lockout, turn off power at the 120 VAC service switch or turn down all thermostats. Wait 45 seconds. Then restore power or call for heat. light flashing alone POWER Usually indicates reversed polarity of 120 VAC power...
  • Page 44 GOLD Troubleshooting — Figure 25 Control module connections High voltage to pilot spark electrode Red wire to gas valve MV Blue wire to gas valve PV Red wires to pressure switch 26037 Gas-Fired Water Boiler control module Black 120 VAC H White 120 VAC N 120 VAC to...
  • Page 45 POWER at service switch or breaker. POWER light flashing now? Have system checked by a licensed electrician. If problem persists, call your local Weil-McLain sales Boiler should now representative. operate normally. Part number 550-110-260/0200 control module lights POWER ▲TURN OFF POWER▲, follow the instructions.
  • Page 46 GOLD Troubleshooting — CHART 2 — TSTAT CIRC & POWER lights flashing — Usually indicates 48 VAC on thermostat circuit (stray voltage) — Electrical shock hazard — Wherever you see instructions could result in severe personal injury, death or substantial property damage. •...
  • Page 47 Boiler Manual continued CHART 3 — PRESS SWITCH & POWER lights flashing — Usually indicates pressure switch stuck closed or failed to make within 5 minutes — Electrical shock hazard — Wherever you see instructions could result in severe personal injury, death or substantial property damage. •...
  • Page 48 GOLD Troubleshooting — — Usually indicates flame sensed when it shouldn't be there — Electrical shock hazard — Wherever you see instructions could result in severe personal injury, death or substantial property damage. • Leave main manual gas valve closed. •...
  • Page 49 Boiler Manual continued CHART 5 — FLAME light flashing and POWER light on steady Electrical shock hazard — Wherever you see instructions could result in severe personal injury, death or substantial property damage. • Are main manual shutoff valve and boiler gas valve open? ▲TURN OFF POWER▲...
  • Page 50 GOLD Troubleshooting — CHART 6 — PRESS SWITCH light flashing and POWER light on steady — Usually indicates pressure switch opened during run cycle — — May also be caused by wind gusts in excess of 31 mph for non-direct vent sidewall-vented boilers — Electrical shock hazard —...
  • Page 51 Figure 18.) • If you have less than sufficient heat — Is vent or combustion air piping free of blockage? • Correct conditions and Contact your Weil-McLain recheck operation. sales representative. • See Figure 18, page 31 for normal sequence of operation.

  • Page 52: Replacement Parts

    Trim assembly ... Gas control assembly ... Gas-Fired Water Boiler Replacement parts must be purchased through a local Weil-McLain distributor. When ordering, specify boiler model and size and include description and part number of replacement part. Results from using modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation.

  • Page 58: Dimensions And Ratings

    GOLD Dimensions Figure 31 Dimensional drawing Supply piping ( note 1 Return piping ( note 1 Relief valve, ¾" NPT ½" NPT to expansion tank/air vent 3" Diameter vent A LL DIMENSIONS IN INCHES 13¹⁄₄ 4³⁄₄ NOTE 2 13¹¹ ₁₆ 23¹⁄₄...
  • Page 59 For alternate piping, contact your Weil-McLain sales office. CSA design certified for installation on combustible flooring. Tested for 50 psi working pressure.

  • Page 60: Handling Ceramic Fiber And Fiberglass Materials

    ■ Operations such as sawing, blowing, tear out, and spraying may generate airborne fiber concentration requiring additional protection. ■ Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly. NIOSH stated First Aid. ■ Eye: Irrigate immediately ■ Breathing: Fresh air. Weil-McLain 500 Blaine Street Michigan City, IN 46360-2388 http://www.weil-mclain.com Part Number 550-110-260/0200...

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Gold cgs

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