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Weil-McLain 550-110-260/0107 manual

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Table of contents for the manual

  • Page 1

    P ar t No . 550-110-260/0107 This manual must only be used by a qualified heating installer/ser vice technician. Before installing , read all instructions, including this manual, the burner manual and any related supplements. P erform steps in the order given. Failur e to comply c ould result in sever e personal injury , death or substantial prope[...]

  • Page 2

    Part number 550-110-260/0107 2 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual How it works . . . ① Control module The control module responds to signals from the room ther mostat, air pr essure sw itch and boiler limit circuit to operate the boiler circulat or , pilot burner , g as valve and inducer . Whe n room thermostat calls for heat, the[...]

  • Page 3

    Part number 550-110-260/0107 3 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual GOLD CGs Gas-Fir ed Induced-Draft W ater Boiler[...]

  • Page 4

    Part number 550-110-260/0107 4 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Contents Hazar d definitions The following defined terms ar e used throughout this manual to bring attention to the presence of hazards of various risk le v els or to important information concerning the life of the product. Indicates presence of hazards that will c[...]

  • Page 5

    Part number 550-110-260/0107 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 inst ructions in prop er order to pre vent p ers ona l injury or death. • A lso refer to CGs V enting Supplements . • C on sid er pi pin g an d ins tal lat ion when[...]

  • Page 6

    Part number 550-110-260/0107 6 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual P r e p a r e b o i l e r l o c a t i o n — codes & checklist 1a Installations must follow these codes: • Local, state, provincial, and national codes, laws, regulations and or dinances. • N ational Fuel Gas Code, ANSI Z223.1–latest edition. • Standard f[...]

  • Page 7

    Part number 550-110-260/0107 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. Pr ovide clearances for cleaning and servicing the boiler and for acc ess t o c on[...]

  • Page 8

    Part number 550-110-260/0107 8 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler location — vent system 1c Failur e to follow all inst ructions can result in flue gas spillage and carbon mono xide emissions, causing se v ere personal injury or death. W he n r em o vi n g b oi l e r f r o m a n e xi s ti n g c o mm o n v en t sy[...]

  • Page 9

    Part number 550-110-260/0107 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 pr event potential of sever e personal injury or death, check for products or areas listed below befor e installing boiler . If an y of these contami[...]

  • Page 10

    Part number 550-110-260/0107 10 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Pr epar e boiler location — air openings 1e Special considerations Tight construction A NS I Z 2 23 . 1 d ef i ne s u nu s ua l ly t ig h t c on st r u ct i on where: 1. W a lls and ce iling s exp osed to t he ou tside at mo- sphere have a continuous water vapor re[...]

  • Page 11

    Part number 550-110-260/0107 11 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Figure 3 Sizing air openings for CGs installations ✷[...]

  • Page 12

    Part number 550-110-260/0107 12 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Place boiler/crate near position 1. Lea ve boiler in crate and on pallet until installation site is read y . 2. M ove entire cr ate and pallet next to selected lo ca- tion. 3. R emove crate. 4. R emove boiler fr om pallet. Do not dro p boiler or bump j ack et on flo[...]

  • Page 13

    Part number 550-110-260/0107 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 tes t boil er bef or e attaching water or gas piping (ex cept as noted below) or electrical supply . Prepar e boiler for test 1. R emove the shipping nipple (fr om CGs supply tap- pin g) and[...]

  • Page 14

    Part number 550-110-260/0107 14 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual W ater piping — general information 3a T able 3 Water pipe size (based on 20°F rise) General piping information If installation is to c omply with ASME or Canadian requir ements, an ad- ditional high t emperatur e limit is needed. Install c ontrol in suppl y pipin[...]

  • Page 15

    Part number 550-110-260/0107 15 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Wa te r pi pi ng — s in gl e- zo ne s ys te m 3b Figure 4 Di a p h r a gm - o r b l a dd e r -t y p e e x p a ns i o n t a n k 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 [...]

  • Page 16

    Part number 550-110-260/0107 16 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual W ater piping — multiple zones 3c Piping multiple zones Follo w instruc tions on pages 14 and 15 to install near- boiler or single-zone piping. (Also refer to Piping for radiant heating systems or con ver ted gr avity sys- tems , below , if applicable.) See Figure [...]

  • Page 17

    Part number 550-110-260/0107 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) valves 2 Flow/check val ve 3 Syst em or zone circulat or 5 Zone valv e 6 Drain valve 9 Relief valv[...]

  • Page 18

    Part number 550-110-260/0107 18 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Pip in g — low temp systems 3d Failur e to prevent low return water temperature t o the boiler could cause corrosion of the boiler sections or bur ners, res ulting in severe p ersonal injur y , death or substantial property damage. Radiant heating system piping sho[...]

  • Page 19

    Part number 550-110-260/0107 19 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual 1 Boiler isolation (balancing) valv es 2 Flow/check val ve 3 Syst em or zone circulat or 4 Syst em temperature gauges 5 Zone valv e 6 Drain valve 7 Syst em temperature valves (see instruc- tions to the left for adjusting val ves) 8 Blend temperature gauge 9 Relief va[...]

  • Page 20

    Part number 550-110-260/0107 20 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Failur e to prevent low return water temperature t o the boiler could cause corrosion of the boiler sections or bur ners, res ulting in severe p ersonal injur y , death or substantial property damage. Radiant heating system piping should include a means of regulating[...]

  • Page 21

    Part number 550-110-260/0107 21 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual 1 Boiler isolation (balancing) valv es 2 Flow/check val ve 3 Syst em or zone circulat or 4 Syst em temperature gauges 5 Zone valv e 6 Drain valve 7 Sy stem tempera ture valv es ( see i nstructions to the le ft for adjusting valv es) 8 Blend temperature gauge 9 Relief[...]

  • Page 22

    Part number 550-110-260/0107 22 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Failur e to prevent low return water temperature t o the boiler could cause corrosion of the boiler sections or bur ners, res ulting in severe p ersonal injur y , death or substantial property damage. Radiant heating system piping should include a means of regulating[...]

  • Page 23

    Part number 550-110-260/0107 23 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual 3 Syste m or zone circulato r 7 Syste m temperature valves (see inst ructions to the left for adjusting valv es) 8 Blend temperature gauge 9 Relief valve 10 A utomatic air vent (with diaphrag m-ty pe expan- sion tank), or connect t o tank fitting (closed-t ype ex pa[...]

  • Page 24

    Part number 550-110-260/0107 24 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Ve nt in g an d co mb us ti on a ir 4 CG s Boi ler must be v ent ed and sup pli ed wit h co mbu s- tion and ventilation air as describ ed in W eil-M cLain CGs V enting Supplements pac ked i n envelop e a s- sembly with boiler . Failure to do so w ill cause severe per[...]

  • Page 25

    Part number 550-110-260/0107 25 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Gas piping 5 T able 4 Pipe capacity for 0.60 specific gravity natural gas Natural Gas: 1. R efer to T able 4 for pipe length and diamet er . Base on ra ted b oile r inpu t (di vide b y 1,00 0 to obtai n cubi c feet per hour). T able 4 is o nly for gas with specific[...]

  • Page 26

    Part number 550-110-260/0107 26 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Field wiring 6 Thermostat 1. Connect thermostat as sho w n on w iring diagr am on boiler . 2. Install on inside wall aw ay from influences of draf ts, hot or cold water pipes, lighting fixt ures, television, sunra ys, or fir eplaces. 3. If thermostat has a heat an[...]

  • Page 27

    Part number 550-110-260/0107 27 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Start-up — pr eparation 7a Fill the system with water 1. Close manual and auto matic air vents and boiler drain cock. 2. Fill to correct system pressure . Co rrec t pr e ss ur e w i ll v a r y w i t h e ac h a pp li c at i o n. T y pi cal cold w ate r fill pr essu[...]

  • Page 28

    Part number 550-110-260/0107 28 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Start-up — operate boiler 7b Inspect system water piping Aft er filling the boiler an d sy stem with wate r , inspec t all piping th roughout the system for leaks. I f found, repair immediately . R epeat this inspection after the boiler has been started and the sy[...]

  • Page 29

    Part number 550-110-260/0107 29 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Start-up — operate boiler (continued) 7b Figure 16 T ypical pilot burner flame Figure 17 T ypical main burner flame Check bur ner flames V iew pilot and ma in fla mes through the i nspection port in the A ir inlet box front c ove r . Pilot burner flame ( Figur[...]

  • Page 30

    Part number 550-110-260/0107 30 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Check-out pr ocedur e — checklist 8 ❏ Boiler and heat distribution units filled w ith water? ❏ A utomatic air v ent, if used, o pen one full turn? ❏ Air purged from sy stem? ❏ Air purged from gas piping? Piping c hecked for leaks? ❏ Correc[...]

  • Page 31

    Part number 550-110-260/0107 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 appropr iat e Operating instructions i n Section 9c . This infor mation is also lo cated on a label on the inside of the boiler jack et door panel. 2. Raise [...]

  • Page 32

    Part number 550-110-260/0107 32 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Operation — wiring diagrams 9b Figure 19 Schematic wiring diagram[...]

  • Page 33

    Part number 550-110-260/0107 33 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Figure 20 Ladder wiring diagram[...]

  • Page 34

    Part number 550-110-260/0107 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: Hone ywell VR8204/VR8304[...]

  • Page 35

    Part number 550-110-260/0107 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-Rodgers 36E 9c[...]

  • Page 36

    Part number 550-110-260/0107 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-Rodgers 36C[...]

  • Page 37

    Part number 550-110-260/0107 37 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual T able 5 Service and maintenance schedules Service and maintenance — schedule 10a Follo w the Service and maintenance procedur es given throughout this manual and in com- ponent literature shipped with the b oiler . Failure to p erform the ser vice and maintenance [...]

  • Page 38

    Part number 550-110-260/0107 38 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Service & maintenance — annual start-up 10b Air openings 1. V erify that comb ustion and v entilati on air open ings to the b oiler room and/or building are open and unobstr ucted . 2. V erify that boiler vent discharge is clean and free of obstr uctions . Flue[...]

  • Page 39

    Part number 550-110-260/0107 39 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual ❏ Inspect . . . Burners, base and inlet air box Th e b oil er co nta in s ce ra mi c fib er a nd fi be rg la ss materials. U se care when handling these mat erials per instr uctions on page 68 of this manual. Failur e to co mply could result in sev ere personal i[...]

  • Page 40

    Part number 550-110-260/0107 40 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Service & maint. — annual start-up continued 10b ❏ Check/test . . . Gas piping 1. Sniff near floor and around boiler area for an y in- dication of a gas leak . 2. T est gas piping using bubble test, per Sect ion 5 of this manual, if there is any indication o[...]

  • Page 41

    Part number 550-110-260/0107 41 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Safety relief val ves should be reinspected A T LEAST ONCE EVER Y THREE YEARS , by a licensed plumbing contra ctor or authori zed inspection ag ency , to ensur e that the pr oduct has not been affected b y corrosi ve water conditions and to ensure that the val ve and[...]

  • Page 42

    Part number 550-110-260/0107 42 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Service & maint. — annual start-up 10b ❏ Review with owner 1. R ev iew the User’ s Information Manual w ith the owner . 2. Emphasize the need to perform the maintenance s c h e du l e s p e c i f i e d i n t h e User’ s Information Manual (and in this man[...]

  • Page 43

    Part number 550-110-260/0107 43 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — pr ocedure 11a Label all wires prior t o disc onnection when servicing c ontro ls. W iring errors can cause impr oper and dangerous operation. Nev er ju mper (byp ass) rollout t hermal fuse elem ent or any other device ex cept for momentar y tes[...]

  • Page 44

    Part number 550-110-260/0107 44 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — air pr essure switch 11b Air pr essure switch Mak e s ure boiler wat er t emperature is 100 °F or cooler b efore st artin g pr oc ed u re t o o b ta i n a p pro pr i a te readings. Check pressur e switch setting 1. See Figur e 24 and T able 6 .[...]

  • Page 45

    Part number 550-110-260/0107 45 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual T r oubleshooting — contr ol module 11c Contr ol module So lde r or wa te r spl att er betw een plu gs and cir cui t boa rd can c aus e impr ope r oper atio n of c ontr ol m odul e. Plac e a shield ove r the boiler internal control s and compone nts during installa[...]

  • Page 46

    Part number 550-110-260/0107 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 550-110-260/0107 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 see ▲ TURN OFF POWER ▲ , follow the instructions. Fai lu re to follow instructions could result in severe personal injury, de[...]

  • Page 48

    Part number 550-110-260/0107 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 injury, death or substantial property damage. CHART 2 — TSTAT CIRC[...]

  • Page 49

    Part number 550-110-260/0107 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 s TURN OFF POWER s , follow the instructions. Failure to follow instructions could result in severe personal inj[...]

  • Page 50

    Part number 550-110-260/0107 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 instr uctions in this manual (Section 9c ). • [...]

  • Page 51

    Part number 550-110-260/0107 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 lo cation). • Verify inlet gas pressure at gas valve: Natural gas — 5.0" w.c. min [...]

  • Page 52

    Part number 550-110-260/0107 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 instructions. Failure to follow instructions could result in sev[...]

  • Page 53

    Part number 550-110-260/0107 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 550-110-260/0107 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 550-110-260/0107 55 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Replacement parts — section assembly 12b Figure 26 Section assembly[...]

  • Page 56

    Part number 550-110-260/0107 56 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Replacement parts — base 12c Figure 27 Base assembly[...]

  • Page 57

    Part number 550-110-260/0107 57 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Replacement parts — base (continued) 12c Item Description Weil-McLain part number Base insulation kit (includes insul ation for all base parts above plus gasket material needed between bloc k assembly and base) CGs-3 CGs-4 CGs-5 CGs-6 381 -356-515 381 -356-516 381 [...]

  • Page 58

    Part number 550-110-260/0107 58 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Replacement parts — jacket 12d Figure 28 Jacket assembly[...]

  • Page 59

    Part number 550-110-260/0107 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 insulation Panel, right side , with insulation Panel, top fr ont , with insulation Panel, top r ear , with insulation Panel, door Natural Gas Propane Gas W eil-McLain part number CGs-3 [...]

  • Page 60

    Part number 550-110-260/0107 60 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Replacement parts — trim 12e Figure 29 T rim assembly Item number Description Manufacturer Manufacturer ’ s part number Weil-McLain part num ber 1 Pressur e relief valve, ASME, 30 PSIG, ¾" male inlet Pressure r elief valve, ASME, 30 PSIG, ¾ " female i[...]

  • Page 61

    Part number 550-110-260/0107 61 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Replacement parts — contr ols 12f Figure 30 Gas control assembly Item number Description Manufacturer Manufacturer ’ s part number Weil-McLain part number Natural gas components 1 Gas valve, ½" x ½", CGs-3 through CGs-6 Honeywell VR8204A20 0 1 51 1-04[...]

  • Page 62

    Part number 550-110-260/0107 62 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Dimensions 13a Figure 31 Dimensional drawing[...]

  • Page 63

    Part number 550-110-260/0107 63 GOLD CGs Gas-Fired W ater Boiler — Boiler Manual Ratings T able 7 Boiler ratings DOE 13b (N ote 5) CGs boilers for r esidential radiant panel systems, con verted gravity heating system s or other low water tempera- ture applications should be installed w ith balancing valves and by pass piping equal to the supply a[...]

  • Page 64

    64 Part Number 550-110-260/0107 GOLD CGs Gas-F ired W ater Boiler — Boiler Manual Handling ceramic fiber and fiber glass materials REMOV AL OF COMBUSTION CHAMBER LINING OR BASE P ANELS The combustion chamber li ning or base insulation pane ls in this prod- uct c ontain ce ramic fiber mat erials. C er a m i c f i b e rs c a n b e c onv e r te d[...]