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Weil-McLain GOLD CGS 550-110-260/0107 Manual

Weil-McLain GOLD CGS 550-110-260/0107 Manual

Gas-fired water boilers
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Boiler Manual
This manual must only be used by a qualified heating installer/service technician.
instructions, including this manual, the burner manual and any related supplements. Perform steps in the order
given. Failure to comply could result in severe personal injury, death or substantial property damage.
DO NOT USE BOILER DURING CONSTRUCTION
follow the requirements given on page 9. Failure to comply could result in severe personal injury, death or sub-
stantial property damage.
GOLD CGs
Gas-Fired Water Boilers
• Installation
• Startup
unless you provide dust-free air to the boiler area or
• Maintenance
• Parts
Before installing
, read all
Part No. 550-110-260/0107

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Summary of Contents for Weil-McLain GOLD CGS 550-110-260/0107

  • Page 1 GOLD CGs Gas-Fired Water Boilers Boiler Manual • Installation • Maintenance • Startup • Parts Before installing This manual must only be used by a qualified heating installer/service technician. , read all instructions, including this manual, the burner manual and any related supplements. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage. DO NOT USE BOILER DURING CONSTRUCTION unless you provide dust-free air to the boiler area or follow the requirements given on page 9. Failure to comply could result in severe personal injury, death or sub- stantial property damage.

  • Page 2: How It Works

    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 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. The control module allows up to 15 seconds to establish pilot flame. If flame is not sensed within 15 seconds, the control module will turn off the gas valve, flash the Flame light, and then enter a 15-second postpurge. The control module will then start a new cycle. This will continue indefinitely until pilot flame is established or power is interrupted. Once pilot flame is proven, the control module opens the gas valve to allow main burner flame. When the room thermostat is satisfied, the control module turns off the gas valve, operates the inducer for a 15-second postpurge and waits for the next heat call. The control module indicator lights show normal sequence when the lights are on steady. When a problem occurs, the control module flashes combinations of lights to indicate the most likely reason for the problem (see page 45). ② Transformer The control transformer reduces line voltage to 4 volts for the gas valve and limit circuit. ③ Inducer The inducer pulls flue gases through the boiler, causing air to be pulled in through the air intake opening. The inducer pushes the flue gases through the vent pipe as well. ④ Air pressure switch The air pressure switch signals the control module, telling the control module whether air is moving through the inducer.
  • Page 3 GOLD CGs Gas-Fired Water Boiler — Boiler Manual GOLD CGs Gas-Fired Induced-Draft Water Boiler Part number 550-110-260/0107...

  • Page 4: Table Of Contents

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual 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 ............25 6 Field wiring ............26 7 Start-up ............27–29 8 Check-out procedure ......... 30 9 Operation .............31–36 10 Service and maintenance ......37–42 11 Troubleshooting .

  • Page 5: Please Read Before Proceeding

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Please read before proceeding Installer User This manual is for use only by your qualified • Read all instructions before in- heating installer/service technician. stalling. Follow all instructions in User’s Information Manual • Please refer to the for proper order to prevent personal your reference.
  • Page 6 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — codes & checklist Installations must follow these codes: • Local, state, provincial, and national codes, laws, regulations and ordinances. • National Fuel Gas Code, ANSI Z3.1–latest edition. • Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ ASME CSD-1, when required. • National Electrical Code. • For Canada only: B149.1 or B149. Installation Code, CSA C.1 Canadian Electri- cal Code Part 1 and any local codes. The CGs boiler gas manifold and controls met safe lighting and other performance criteria when boiler underwent tests specified in ANSI Z1.13–latest edition. Before locating the boiler, check the following: • Check for nearby connection to: • System water piping • Venting connections • Gas supply piping • Electrical power Remove any combustible materials, gasoline and • Check area around boiler.

  • Page 7: Prepare Boiler Location

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — clearances Recommended SERVICE clearances Figure 2 Required MINIMUM clearances (Fig. 1) 1. Provide clearances for cleaning and servicing the boiler and for access to controls and components. See Figure 1 for recommenda- tions. . Provide at least screwdriver clearance to jacket front panel screws for removal of front panel for inspection and minor service. If unable to provide at least screwdriver clearance, install unions and shutoff valves in system so boiler can be moved for servicing. Figure 1 Recommended SERVICE clearances (see WARNING below) Flooring The CGi boiler is approved for installation on combustible flooring, but must never be installed on carpeting.

  • Page 8: Prepare Boiler

    After it has been determined that flue, using either: remaining connected to the common venting system Vertical direct vent installation. Obtain the properly vents when tested as outlined above, return Weil-McLain Through-Roof or Through-Unused doors, windows, exhaust fans, fireplace dampers, Chimney termination kit and supplement. Refer and any other gas-burning appliance to their previ- Vertical Direct Venting Venting Supplement, ous conditions of use.
  • Page 9 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — contamination Table 1 Please review the following information on potential Refer to for products and areas which may cause combustion air contamination problems. contaminated combustion air. To prevent potential of severe personal injury or death, check for products or areas listed below before installing boiler. If any of these contaminants are found: • remove contaminants permanently — OR — • isolate boiler and provide outside combustion air. See national, provincial or local codes for further information. Table 1 Corrosive or destructive contaminants and likely locations Products to avoid Areas likely to have contaminants Spray cans containing chloro/fluorocarbons Dry cleaning/laundry areas and establishments...
  • Page 10 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air openings mended in Figure 3 will allow adequate ventilation and Combustion air opening location and sizing combustion air provided the boiler room is not sub- requirements depend on the clearances around jected to negative pressure due to exhaust fans or other the boiler. Check the boiler placement compared to mechanical ventilation devices. Refer to the National ✷ Figure 1, page .
  • Page 11 GOLD CGs Gas-Fired Water Boiler — Boiler Manual ✷ Figure 3 Sizing air openings for CGs installations Part number 550-110-260/0107...
  • Page 12 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Prepare boiler — placement & setup Place boiler/crate near Inlet air box top panel must be in position during boiler operation. position Failure to do so could result in severe personal injury, death or 1. Leave boiler in crate and on pallet until installation substantial property damage. site is ready. . Move entire crate and pallet next to selected loca- tion. 3. Remove crate. Orifice replacement procedure 4. Remove boiler from pallet. Do not drop boiler or bump jacket (when required) on floor or pallet. Damage to boiler...
  • Page 13 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Prepare boiler — pressure test Hydrostatic pressure test 5. Slowly reopen boiler drain valve until test pressure on the pressure/temperature gauge reaches no more Pressure test boiler before attaching water or gas piping than: (except as noted below) or electrical supply. • 45 psig for boilers with 30 psig relief valve Prepare boiler for test • 75 psig for boilers with 50 psig relief valve 1. Remove the shipping nipple (from CGs supply tap- Test for no more than 10 minutes at: Temporarily ping) and remove the boiler relief valve.

  • Page 14: Water Piping

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Water piping — general information General piping information Circulator If installation is to comply with ASME or Canadian requirements, an ad- The circulator is shipped loose (wiring pre-attached to ditional high temperature limit is needed. Install control in supply piping boiler) to allow you to locate it either in the return or between boiler and isolation valve. Set second control to minimum 0°F supply piping, as desired. See page 3 for a typical instal- above setpoint of first control. Maximum allowable setpoint is 40°F. See lation. Pipe the expansion tank to the suction side of the Section , page 3 for wiring. circulator whenever possible. Install an air separator in low water cutoff device is required when boiler is installed above ra- the supply piping. Connect the expansion tank to the air diation level or by certain state or local codes or insurance companies. Use separator only if the separator is on the suction side of low water cutoff designed for water installations. Electrode probe-type is the circulator. Always install the system fill connection recommended. Purchase and install in tee in supply piping above boiler.
  • Page 15 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Water piping — single-zone system Diaphragm-type or bladder- Closed-type expansion tank type expansion tank (Figure 4) (Figure 5) 1. Ensure expansion tank size will handle boiler and 1. Ensure expansion tank size will handle boiler and system water volume and temperature. Tank must system water volume and temperature. See tank be located in boiler return piping as close to boiler manufacturer’s instructions for details. as possible, before inlet side of circulator. See tank . Connect tank to ½” NPT tapping located behind manufacturer’s instructions for details. supply outlet, using ½” NPT piping. Pitch any automatic air vent . Install an in air vent tapping as...
  • Page 16 . Provide a separate 4-volt transformer to power the method of either on page 1. Do not use the piping of Figure 12 (system-bypass), zone valves. Size the transformer to handle the total because this method does not control radiant system rated load of all connected zone valves. supply temperature. heat If radiant system tubing has no oxygen barrier, a exchanger must be used. Radiant heating system piping should include a means of regulating the boiler return water temperature and the system supply temperature (such as provided by an injection pumping control). Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the system supply temperature is relatively constant. DO NOT outdoor reset apply the methods in this manual if the system is equipped with an control . Instead, provide controls and piping which can regulate the boiler return water temperature at no less than 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 dam- age. Part number 550-110-260/0107...
  • Page 17 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Water piping — multiple zones (continued) Figure 6 Zoning with circulators Figure 7 Zoning with zone valves — return water 130°F or higher. — return water 130°F or higher. Boiler isolation (balancing) Automatic air vent (with diaphragm-type expansion tank), or connect valves to tank fitting (closed-type expansion tank).
  • Page 18 DO NOT apply the methods of this manual if the system is equipped with an reset control. provide controls and piping regulate the boiler re- Instead, which can turn water temperature at no less than 130°F regardless of system supply temperature. Contact your Weil-McLain representative for suggested piping and control methods. prevent cold return water temperature Failure to to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage. Part number 550-110-260/0107...
  • Page 19 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Piping — low temp systems (continued) Figure 8 Primary/secondary piping Figure 9 Primary/secondary piping Zoning with circulators Zoning with zone valves Relief valve Boiler isolation (balancing) valves Automatic air vent (with diaphragm-type expansion tank), or Flow/check valve DO NOT connect to tank fitting (closed-type expansion tank). use an automatic air vent when using closed-type expansion System or zone circulator tank. It would allow air to leave the system, causing waterlog- ging of the expansion tank. System temperature gauges Fill valve Zone valve...
  • Page 20 DO NOT apply the methods of this manual if the system is equipped with an reset control. provide controls and piping regulate the boiler re- Instead, which can turn water temperature at no less than 130°F regardless of system supply temperature. Contact your Weil-McLain representative for suggested piping and control methods. prevent cold return water temperature Failure to to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage. Part number 550-110-260/0107...
  • Page 21 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Piping — low temp systems (continued) Figure 10 Boiler-bypass piping Figure 11 Boiler-bypass piping Zoning with circulators Zoning with zone valves Alternative to primary/secondary piping (Alternative to primary/secondary piping Figures 8 and 9) Figures 8 and 9) Boiler isolation (balancing) valves Automatic air vent (with diaphragm-type expan-...
  • Page 22 DO NOT apply the methods of this manual if the system is equipped with an reset control. provide controls and piping regulate the boiler re- Instead, which can turn water temperature at no less than 130°F regardless of system supply temperature. Contact your Weil-McLain representative for suggested piping and control methods. prevent cold return water temperature Failure to to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage. Part number 550-110-260/0107...

  • Page 23: Water Piping

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Piping — low temp systems (continued) Figure 12 System-bypass piping Zoning with zone valve or circulators, return water 130°F or higher. (Alternative to boiler-bypass piping Figures 10 and 11, page 21) 3 System or zone circulator 7 System temperature valves (see instructions to the left for adjusting valves) 8 Blend temperature gauge...

  • Page 24: Venting & Combustion Air

    Venting Supplements and to manual Section regarding require- ments for: • vent system • combustion air openings • combustion air quality CGs Boiler must be vented and supplied with combus- tion and ventilation air as described in Weil-McLain Venting Supplements CGs packed in envelope as- sembly with boiler. Failure to do so will cause severe personal injury or death. Use direct vent (sealed combustion) if combustion air quality cannot be assured to be free of contaminants Refer to page 9 for a list of potential contaminants and locations likely to contain them. Operating the boiler...

  • Page 25: Gas Piping

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Gas piping Connecting gas supply piping to boiler Natural Gas: Figure 14 1. Remove jacket front panel and refer to to pipe gas to boiler. 1. Refer to Table 4 for pipe length and diameter. Base Install drip leg at inlet of gas connection to boiler. Where local on rated boiler input (divide by 1,000 to obtain cubic utility requires drip leg to be extended to the floor, use appropri- feet per hour). Table 4 is only for gas with specific ate length of pipe between cap and tee. gravity 0.60, with a pressure drop through the Install ground joint union for servicing, when required.

  • Page 26: Field Wiring

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Field wiring Thermostat turn off electrical power supply at For your safety, service entrance panel before making any electrical 1. Connect thermostat as shown on wiring diagram connections to avoid possible electric shock hazard. on boiler. Failure to do so can cause severe personal injury or death.

  • Page 27: Start-Up

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Start-up — preparation Determine if water treatment is needed Fill the system with water petroleum-based cleaning or sealing com- Do not use air vents 1. Close manual and automatic and pounds in boiler system. Severe damage to boiler will occur, boiler drain cock. resulting in substantial property damage. Fill to correct system pressure . Correct Eliminate all system leaks. Continual fresh makeup water will pressure will vary with each application. reduce boiler life. Minerals can build up in sections, reduc- Typical cold water fill pressure for a residential ing heat transfer, overheating cast iron, and causing section...
  • Page 28 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Start-up — preparation (continued) Inspect system water piping Inspect base insulation insulation is secure Check to make sure against all After filling the boiler and system with water, inspect all four sides of the base. If insulation is damaged or dis- piping throughout the system for leaks. If found, repair do not placed, operate boiler. Replace or reposition immediately. Repeat this inspection after the boiler has insulation. been started and the system has heated up. Failure to replace damaged insu- lation or reposition insulation can...

  • Page 29: Start-Up

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler (continued) If you discover evidence of any gas leak, shut down the Figure 16 Typical pilot burner flame boiler at once. Find the leak source with bubble test and repair immediately. Do not start boiler again until cor- rected. Failure to comply could result in severe personal injury, death or substantial property damage. Check burner flames View pilot and main flames through the inspection port in the Air inlet box front cover. Pilot burner flame ( Figure 16 PROPER pilot flame characteristics 1. Blue flame. . Inner cone engulfing pilot flame sensor. 3. Pilot flame sensor glowing cherry red. IMPROPER pilot flame characteristics: 1. Overfired — Large flame lifting or blowing past pilot flame sensor.

  • Page 30: Check-Out Procedure

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Check-out procedure — checklist ❏ Boiler and heat distribution units filled with water? ❏ Set limit control(s) to system temperature requirements. Adjust balancing valves and controls to provide design ❏ Automatic air vent, if used, open one full turn? temperature to system. ❏ Air purged from system? ❏ For multiple zones, adjust flow so it is about the same in ❏ Air purged from gas piping? Piping checked for leaks? each zone. ❏...

  • Page 31: Operation

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Operation — sequence Read appropriate Operating instructions in erator activates and sequence returns to step Section . This information is also located on a If power is interrupted , control system shuts label on the inside of the boiler jacket door panel. pilot and main gas valves and restarts at step when power is restored. Raise room thermostat to call for heat. limit control shuts down the 6. In the event the Circulator energizes.
  • Page 32 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Operation — wiring diagrams Figure 19 Schematic wiring diagram Part number 550-110-260/0107...
  • Page 33 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Figure 20 Ladder wiring diagram Part number 550-110-260/0107...

  • Page 34: C Operating Instructions

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Operating instructions • Spark pilot • Natural or propane gas CGs-3 to CGs-6 • Gas valve: Honeywell VR8204/VR8304 Part number 550-110-260/0107...
  • Page 35 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Operating instructions • Spark pilot • Natural or propane gas CGs-3 to CGs-6 • Gas valve: White-Rodgers 36E Part number 550-110-260/0107...
  • Page 36 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Operating instructions • Spark pilot • Natural or propane gas CGs-3 to CGi-6 • Gas valve: White-Rodgers 36C Part number 550-110-260/0107...

  • Page 37: Service And Maintenance

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Service and maintenance — schedule VERIFY PROPER OPERATION AFTER SERVICING Table 5 Service and maintenance schedules Follow the Service and maintenance procedures given throughout this manual and in com- ponent literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death or substantial property damage.
  • Page 38 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Service & maintenance — annual start-up Air openings 1. Verify that combustion and ventilation air openings inspected and started annu- The boiler should be to the boiler room and/or building are open and ally only , at the beginning of the heating season, unobstructed by a qualified service technician . In addition, the...
  • Page 39 GOLD CGs Gas-Fired Water Boiler — Boiler Manual ❏ Inspect . . . Condensate drain system 1. Inspect condensate drain fittings and tubing. Verify that condensate can flow freely to drain. Burners, base and inlet air box ❏ Service . . . The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 68 of this manual. Failure Inducer motor to comply could result in severe personal injury. 1. With boiler power , place a few drops of S.A.E. 0 motor oil in each of the two oil cups. If insulation is damaged or displaced, do not operate the boiler. Replace or reposition insulation as neces- S.A.E.
  • Page 40 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Service & maint. — annual start-up continued ❏ Check/test . . . Expansion tank 1. Expansion tanks provide space for water to move in an out as the heating system water expands due to Gas piping temperature increase or contracts as the water cools. Tanks may be open, closed or diaphragm or bladder 1. Sniff near floor and around boiler area for any in- type. See Section of this manual for suggested best gas leak dication of a location of expansion tanks and air eliminators. Test gas piping using bubble test, per Section Open-type — located above highest radiator or...
  • Page 41 GOLD CGs Gas-Fired Water Boiler — Boiler Manual reinspected AT LEAST ONCE EVERY Safety relief valves should be THREE YEARS , by a licensed plumbing contractor or authorized inspection agency, to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally. Certain naturally occurring conditions may corrode the valve or its components over time, rendering the valve inoperative. Such conditions are not detect- able unless the valve and its components are physically removed and inspected. This inspection must only be conducted by a plumbing contractor or authorized inspection agency — not by the owner. Failure to reinspect the boiler relief valve as directed could result in unsafe pressure buildup, which can result in severe personal injury, death or substantial property damage.

  • Page 42: Review With Owner

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Service & maint. — annual start-up ❏ Review with owner . Follow shutdown procedure. 3. Remove venting system connection to boiler. User’s Information Manual 1. Review the with the owner. 4. Remove top jacket panel. Turn back insulation. . Emphasize the need to perform the maintenance 5. Remove collector box/transition assembly. Clean User’s Information schedule specified in the...

  • Page 43: Troubleshooting

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — 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 Troubleshooting device except for momentary testing as outlined in Charts . Severe personal injury, death or substantial property damage can result. Before troubleshooting: 1. Have the following items: a. Voltmeter that can check 10 VAC and 4 VAC. b. Microammeter with a minimum scale range of 0-5. c. Continuity checker. d. U-tube manometer. . Check for 10 VAC (minimum 10 VAC to maximum 13 VAC) to boiler. 3. Make sure thermostat is calling for heat and contacts (including appropriate zone controls) are closed. Check for 4 VAC between thermostat wire nuts and ground.
  • Page 44 Troubleshooting — air pressure switch Air pressure switch Table 6 Pressure switch setpoint (for elevations above 2,000 ft, contact your Make sure boiler water temperature local Weil-McLain sales office for details.) is 100 °F or cooler before starting procedure to obtain appropriate readings. Check pressure switch setting Figure 24 Table 6 1. See...
  • Page 45 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module Control module Control indicator lights — LOCKOUT modes Charts 1 See through in this Section for detailed trouble- Solder or water splatter between plugs and circuit board shooting procedures. can cause improper operation of control module. Place a shield over the boiler internal controls and components To reset control after a lockout, turn off power at the 10 VAC during installation. Failure to comply could result in service switch or turn down all thermostats. Wait 45 seconds. severe personal injury, death or substantial property Then restore power or call for heat.
  • Page 46 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module (continued) Figure 25 Control module connections Part number 550-110-260/0107...
  • Page 47 46) on control module. • Using voltmeter, check across pins of receptacle. Does voltmeter indicate 24 VAC? Have system checked by a licensed electrician. If problem persists, call your local Weil-McLain sales Boiler should now Replace transformer. Replace control module. representative. operate normally.
  • Page 48 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights CHART 2 — TSTAT CIRC & POWER lights flashing — Usually indicates 48 VAC on thermostat circuit (stray voltage) — Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions.
  • Page 49 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights (cont.) 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 sTURN OFF POWERs, follow the instructions.
  • Page 50 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights (cont.) CHART 4 — FLAME & POWER lights flashing — Usually indicates flame sensed when it shouldn't be there — Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions.
  • Page 51 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights (cont.) CHART 5 — FLAME light flashing and POWER light on steady ALSO — Troubleshooting failure to establish main flame Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions.
  • Page 52 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights (cont.) 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 53: Troubleshooting

    Is vent or combustion air piping free of blockage? • Check limit switch • Replace control module. contacts with continuity • Retest. checker. • Correct conditions and Contact your Weil-McLain Are limit switch contacts recheck operation. sales representative. closed? Check rollout switch • See Figure 18, page 31 continuity —...

  • Page 54: Replacement Parts

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Replacement parts Section assembly ..........55 Base ..............56 Jacket ............... 58 Trim ..............60 Controls ............61 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. Weil-McLain Boilers and Weil-McLain part numbers are found in Controls Repair Parts Lists The boiler contains ceramic fiber and fiberglass materials. Use care when...
  • Page 55 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Replacement parts — section assembly Figure 26 Section assembly Part number 550-110-260/0107...
  • Page 56 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Replacement parts — base Figure 27 Base assembly Part number 550-110-260/0107...
  • Page 57 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Replacement parts — base (continued) Item Description Weil-McLain part number Base insulation kit CGs-3 381-356-515 (includes insulation for all base parts above plus gasket material CGs-4 381-356-516 needed between block assembly and base)
  • Page 58 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Replacement parts — jacket Figure 28 Jacket assembly Part number 550-110-260/0107...
  • Page 59 Panel, top rear, Panel, door Junction box, 2 x 4 with insulation with insulation with insulation with insulation Natural Gas Propane Gas Boiler Boiler Model Weil-McLain part number Model CGs-3 (Available at 381-355-701 381-355-729 381-355-699 381-355-403 381-355-706 381-355-707 CGs-3 CGs-4 local supply...
  • Page 60 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Replacement parts — trim Figure 29 Trim assembly Item Description Manufacturer Manufacturer’s Weil-McLain part number number part number Pressure relief valve, ASME, 30 PSIG, ¾" male inlet Conbraco 10-407-10 511-546-920 Watts M330 Pressure relief valve, ASME, 30 PSIG, ¾"...

  • Page 61: Replacement Parts

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Replacement parts — controls Figure 30 Gas control assembly Item Description Manufacturer Manufacturer’s Weil-McLain number part number part number Natural gas components Gas valve, ½" x ½", CGs-3 through CGs-6 Honeywell VR8204A2001...
  • Page 62 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Dimensions Figure 31 Dimensional drawing Part number 550-110-260/0107...
  • Page 63 CGs vent supplements. CGs boilers may be direct-vented (using 3” diameter air piping) as specified in the direct vent supplements. 5. As an Energy Star Partner, Weil-McLain has determined that the CGs-3 meets the Energy Star guidelines for energy efficiency.

  • Page 64: Handling Ceramic Fiber And Fiberglass Materials

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER REMOVAL OF FIBERGLASS WOOL LINING OR BASE PANELS The combustion chamber lining or INSTALLATION OF FIBERGLASS WOOL, base insulation panels in this prod- COMBUSTION CHAMBER LINING OR uct contain ceramic fiber materials. Ceramic fibers can be converted to BASE PANELS: cristobalite in very high temperature applications. The International Agency This product contains fiberglass for Research on Cancer (IARC) has...

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