1. Manuals
  2. Brands
  3. Weil-McLain Manuals
  4. Boiler
  5. GOLD CGS 550-110-260/0508
  6. User manual

Weil-McLain GOLD CGS 550-110-260/0508 User Manual

Gas-fired water boilers
Hide thumbs
Table of Contents

Advertisement

Quick Links

Boiler Manual
This manual must only be used by a qualifi ed 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
or follow the requirements given on page 9. Failure to comply could result in severe personal injury, death or
substantial property damage.
GOLD CGs
Gas-Fired Water Boilers
• Installation
• Startup
unless you provide dust-free air to the boiler area
• Maintenance
• Parts
, read all
Before installing
Part No. 550-110-260/0508

Advertisement

Table of Contents
loading

Related Manuals for Weil-McLain GOLD CGS 550-110-260/0508

Summary of Contents for Weil-McLain GOLD CGS 550-110-260/0508

  • Page 1 Boiler Manual This manual must only be used by a qualifi ed 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 or follow the requirements given on page 9.

  • 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.
  • Page 3 GOLD CGs Gas-Fired Water Boiler — Boiler Manual GOLD CGs Gas-Fired Induced-Draft Water Boiler Part number 550-110-260/0508...

  • Page 4: Table Of Contents

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Contents How it works ...2–3 Hazard defi nitions ... 4 Please read before proceeding ... 5 Prepare boiler location ...6–11 Prepare boiler ...12–13 Water piping ...14–23 Venting & combustion air ... 24 Gas piping ...

  • Page 5: Please Read Before Proceeding

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Please read before proceeding Installer Read all instructions before in- stalling. proper order to prevent personal injury or death. • Also refer to CGs • Consider piping and installation boiler location. • claims for damage or shortage in shipment must be fi...
  • 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 Z223.1–latest edition. • Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ ASME CSD-1, when required.

  • Page 7: Prepare Boiler Location

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — clearances Recommended SERVICE 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. 2.

  • Page 8: Prepare Boiler

    fl ue products into the living space. terminate at the same location as the ALWAYS installation. Obtain the Vertical direct vent Weil-McLain Through-Roof or Through-Unused termination kit and supplement. Refer Chimney Venting Supplement, Vertical Direct Venting packed with the kit, and to the vent manufacturer’s...
  • Page 9 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — contamination Please review the following information on potential combustion air contamination problems. Table 1 Corrosive or destructive contaminants and likely locations Products to avoid Spray cans containing chloro/fluorocarbons Permanent wave solutions Chlorinated waxes/cleaners Chlorine-based swimming pool chemicals...
  • Page 10 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air openings Combustion air opening location and sizing requirements depend on the clearances around Check the boiler placement compared to the boiler. ✷ Figure 1, page 7. If all clearances are at least equal to Figure 1, , apply the sizing and placement of openings page 7 given on pages 10 and 11.
  • Page 11 GOLD CGs Gas-Fired Water Boiler — Boiler Manual ✷ Figure 3 Sizing air openings for CGs installations Part number 550-110-260/0508...
  • Page 12 Table 2 Manifold orifi ce sizing Location U. S. Canada Note 1: For elevations above 2,000 feet, contact your local Weil-McLain sales office for details. Orifi ce replacement procedure (when required) 1. Remove the screws securing the inlet air box top panel.
  • Page 13 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Prepare boiler — pressure test Hydrostatic pressure test Pressure test boiler before (except as noted below) or electrical supply. Prepare boiler for test 1. Remove the shipping nipple (from CGs supply tap- 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 If installation is to comply with ASME or Canadian requirements, an ad- ditional is needed. Install control in supply piping high temperature limit between boiler and isolation valve. Set second control to minimum 20°F above setpoint of fi...
  • Page 15 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Water piping — single-zone system Diaphragm-type or bladder- type expansion tank 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: Piping Multiple Zones

    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 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Water piping — multiple zones Figure 6 Zoning with circulators — return water 130°F or higher. Boiler isolation (balancing) valves Flow/check valve System or zone circulator Zone valve Drain valve Relief valve Part number 550-110-260/0508 Figure 7 Automatic air vent (with diaphragm-type expansion tank), or connect...
  • Page 18 130°F Contact your Weil-McLain representative for suggested piping and control methods. Failure to prevent cold return water temperature damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.
  • Page 19 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Piping — low temp systems Figure 8 Primary/secondary piping Zoning with circulators Boiler isolation (balancing) valves Flow/check valve System or zone circulator System temperature gauges Zone valve Drain valve System temperature valves (see instruc- tions to the left for adjusting valves) Blend temperature gauge Part number 550-110-260/0508...
  • Page 20 130°F Contact your Weil-McLain representative for suggested piping and control methods. Failure to prevent cold return water temperature damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.
  • Page 21 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Piping — low temp systems Figure 10 Boiler-bypass piping Zoning with circulators Alternative to primary/secondary piping Figures 8 and 9) Boiler isolation (balancing) valves Flow/check valve System or zone circulator System temperature gauges Zone valve Drain valve System temperature valves (see instructions to the left...
  • Page 22 130°F Contact your Weil-McLain representative for suggested piping and control methods. Failure to prevent cold return water temperature damage to the sections or burners, resulting in possible severe personal injury, death or substantial property damage.

  • Page 23: Water Piping

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Piping — low temp systems Water piping — refrigeration systems Figure 13 Piping refrigeration systems System supply Circulator System return 26019 Part number 550-110-260/0508 Figure 12 3 System or zone circulator 7 System temperature valves (see instructions to the 8 Blend temperature gauge 9 Relief valve 10 Automatic air vent (with diaphragm-type expan-...

  • Page 24: Venting & Combustion Air

    V enting Supple- and to manual Section regarding require- CGs Boiler must be vented and supplied with combus- as described in Weil-McLain tion and ventilation air packed in envelope as- Venting Supplements sembly with boiler. Failure to do so will cause severe personal injury or death.

  • Page 25: Gas Piping

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Gas piping Connecting gas supply piping to boiler 1. Remove jacket front panel and refer to at inlet of gas connection to boiler. Where local Install drip leg utility requires drip leg to be extended to the fl oor, use appropri- ate length of pipe between cap and tee.

  • Page 26: Field Wiring

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Field wiring For your safety, turn off electrical power supply at service entrance panel before making any electrical to avoid possible electric shock hazard. connections 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 Do not use petroleum-based cleaning or sealing com- in boiler system. Severe damage to boiler will occur, pounds resulting in substantial property damage. Eliminate all system leaks.

  • Page 28: Start The Boiler

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Start-up — preparation Inspect system water piping After fi lling the boiler and system with water, throughout the system for leaks. If found, repair piping immediately. Repeat this inspection after the boiler has been started and the system has heated up.

  • Page 29: Start-Up

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler 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 cor- rected.

  • Page 30: Check-Out Procedure

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Check-out procedure — checklist ❏ Boiler and heat distribution units fi lled with water? ❏ Automatic air vent, if used, open one full turn? ❏ Air purged from system? ❏ Air purged from gas piping? Piping checked for leaks? ❏...

  • Page 31: Operation

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Operation — sequence Read appropriate Operating instructions Section . This information is also located on a label on the inside of the boiler jacket door panel. room thermostat to call for heat. Raise Circulator energizes.
  • Page 32 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Operation — wiring diagrams Figure 19 Schematic wiring diagram Part number 550-110-260/0508...
  • Page 33 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Figure 20 Ladder wiring diagram Part number 550-110-260/0508...

  • Page 34: C Operating Instructions

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Operating instructions CGs-3 to CGs-6 • Spark pilot • Natural or propane gas • Gas valve: Honeywell VR8204/VR8304 Part number 550-110-260/0508...
  • Page 35 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Operating instructions CGs-3 to CGs-6 Part number 550-110-260/0508 • Spark pilot • Natural or propane gas • Gas valve: White-Rodgers 36E...
  • Page 36 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Operating instructions CGs-3 to CGi-6 • Spark pilot • Natural or propane gas • Gas valve: White-Rodgers 36C Part number 550-110-260/0508...

  • 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 Service technician (see following pages for instructions) Inspect: • Reported problems • Boiler area • Air openings •...
  • Page 38 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Service & maintenance — annual start-up The boiler should be , at the beginning of the heating season, ally by a qualifi ed service technician maintenance and care of the boiler designated in , page 37,and explained on the following Table 5 pages must be performed to assure maximum boiler...
  • Page 39 GOLD CGs Gas-Fired Water Boiler — Boiler Manual ❏ Inspect . . . Burners, base and inlet air box The boiler contains ceramic fi ber and fi berglass materials. Use care when handling these materials per instructions on page 68 of this manual. Failure to comply could result in severe personal injury.
  • Page 40 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Service & maint. — annual start-up ❏ Check/test . . . Gas piping 1. Sniff near fl oor and around boiler area for any in- dication of a Test gas piping using bubble test, of this manual, if there is any indication of a leak.
  • Page 41 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Safety relief valves should be , by a licensed plumbing contractor or authorized THREE YEARS 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.

  • Page 42: Review With Owner

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Service & maint. — annual start-up ❏ Review with owner 1. Review the User’s Information Manual owner. 2. Emphasize the need to perform the maintenance schedule specified in the (and in this manual as well). Manual 3.

  • Page 43: Troubleshooting

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — procedure Before troubleshooting: 1. Have the following items: a. Voltmeter that can check 120 VAC and 24 VAC. b. Microammeter with a minimum scale range of 0-25. c. Continuity checker. d.

  • Page 44: Air Pressure Switch

    Table 6 Figure 24 ), but there is not 24 VAC between Table 6 Pressure switch setpoint (for elevations above 2,000 ft, contact your local Weil-McLain sales offi ce for details.) Boiler model number Inches W.C. CGs-3 1.79" CGs-4 1.48"...
  • Page 45 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module Control module splatter between plugs and circuit board Solder or water can cause improper operation of control module. Place a shield over the boiler internal controls and components during installation.
  • Page 46 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module Figure 25 Control module connections (continued) Part number 550-110-260/0508...
  • Page 47 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 550-110-260/0508 POWER ▲TURN OFF POWER • Make sure service switch or circuit breaker is on or fuses are good.
  • 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 instructions could result in severe personal injury, death or substantial property damage.
  • Page 49 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights 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 50 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights — 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. •...
  • Page 51 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights 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. •...
  • Page 52 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Troubleshooting — control module lights 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

    Figure 18, page 31.) • 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 54: Replacement Parts

    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 modifi ed or other manufactured parts will not be covered by warranty and may damage boiler or impair operation.
  • Page 55 Radiation plate (1 per joint) Collector hood and transition assembly High limit, 30˚ differential, with well Inducer fan assembly kit, includes inducer fan assembly, gasket and nuts Gasket, inducer Part number 550-110-260/0508 Weil-McLain part number 311-103-830 311-103-821 311-103-818 CGs-3 321-114-345...
  • Page 57 Grommet for sealing pilot tubing/wiring opening to Air box Inspection port clear plug Hex nut for burner end stud, 5 mm Gasket (for Air inlet box covers), 8-foot length Part number 550-110-260/0508 (continued) Weil-McLain part number CGs-3 381-356-515 CGs-4 381-356-516...
  • Page 58 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Replacement parts — jacket Figure 28 Jacket assembly Part number 550-110-260/0508...
  • Page 59 431-223-326 381-355-552 CGs-5 431-223-327 381-355-559 CGs-6 431-223-328 381-355-566 Part number 550-110-260/0508 Panel, right side, with insulation with insulation Propane Gas Weil-McLain part number 381-355-729 381-355-699 381-355-732 381-355-699 381-355-735 431-223-311 381-355-738 431-223-311 Panel, rear, Air inlet with insulation fitting Weil-McLain part number...
  • Page 60 Circulator hardware kit, includes: shown 1 flange, 2 nuts, 2 screws, 1 gasket — 1" NPT — CGs-3 through CGs-5 1¼" NPT — CGs-6 Circulator wiring harness kit, with Molex (loose) Manufacturer Manufacturer’s Weil-McLain part number part number Conbraco 10-407-10 511-546-920 Watts M330...

  • Page 61: Replacement Parts

    1.22 I.W.C. — CGs-5 0.95 I.W.C. — CGs-6 Control transformer not shown Tubing, air pressure switch, 0.12 I.D. silicone red, to collector hood white, to transition Part number 550-110-260/0508 Manufacturer Manufacturer’s Weil-McLain part number part number Honeywell VR8204A2001 Weil-McLain Honeywell VR8204M2701 Weil-McLain...

  • Page 62: Dimensions And Ratings

    GOLD CGs Gas-Fired Water Boiler — Boiler Manual Dimensions Figure 31 Dimensional drawing Boiler Supply model tapping number (inches NPT) (inches NPT) CGs-3 1 ¼ CGs-4 1 ¼ CGs-5 1 ¼ CGs-6 1 ¼ Note 3: Gas piping from meter to boiler to be sized per local utility requirements. Return tapping connection size...
  • 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 GOLD CGs Gas-Fired Water Boiler — Boiler Manual Handling ceramic fi ber and fi berglass materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or base insulation panels in this prod- uct contain ceramic fi ber materials. Ceramic fibers can be converted to cristobalite in very high temperature applications.

This manual is also suitable for:

Gold cgs

Table of Contents