Instruction/ maintenance manual of the product GOLD CGS 550-110-260/02002 Weil-McLain
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P art number 550-110-260/0200 2 GOLD CGs Gas-F ired Water Boiler How it works . . . ① Control module The control module responds to signals from the room thermostat, air pressure switch and boiler limit circuit t o operate the boiler circulat or , pilot burner , gas valve and induc er .
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P art number 550-110-260/0200 4 GOLD CGs Gas-F ired Water Boiler Contents Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.
P art number 550-110-260/0200 5 Boiler Manual Please read before proceeding Installer Read all instr uctions befor e installing. Follow all instructions in proper order to prevent personal injury or death. • Also refer to CGs V enting Supplements . • Consider piping and installation when determining boiler location.
P art number 550-110-260/0200 6 GOLD CGs Gas-F ired Water Boiler • Local, state, provincial, and national codes, laws, regulations and ordinances. • N ational Fuel Gas Code, ANSI Z223.1 – latest edit ion. • Standard for Co nt rols and Safety De vices for A utomatically Fired Boilers, ANSI/ASME CSD-1, when required.
P art number 550-110-260/0200 7 Boiler Manual P repare boiler location — clearances 1b Figure 1 Recommended clearances for service Residential garage installation Precautions T ak e the following special precautions when installing the boiler in a residential garage.
P art number 550-110-260/0200 8 GOLD CGs Gas-F ired Water Boiler P repare boiler location — vent system Vent system The CGs boiler requires a special vent system, designed for pressurized venting. Model CGs-3 is rated ANSI Z21.13 Category IV (pressurized vent, likely to condense in the vent).
P art number 550-110-260/0200 9 Boiler Manual P repare boiler location — contamination T able 1 Corrosive contaminants 1d If the boiler is installed in an y area lik ely to cause contamination , or if pr oducts which would contaminate the air cannot be removed, you must pipe combustion air to the boiler air intake.
P art number 550-110-260/0200 10 GOLD CGs Gas-F ired Water Boiler P repare boiler location — air openings 1e Special considerations Tight construction ANSI Z223.
P art number 550-110-260/0200 11 Boiler Manual Figure 3 Sizing air openings for CGs installations Outside Outside or ventilated attic V entilated crawl space Or CGs 12” Max Duct Air from or — Lowe.
P art number 550-110-260/0200 12 GOLD CGs Gas-F ired Water Boiler Place boiler/crate near position 1. Leave boiler in crate and on pallet until installation site is ready . 2 . Move entire crate and pallet next to selected location. 3. Remove crate. 4.
P art number 550-110-260/0200 13 Boiler Manual Pr epare boiler — pr essur e test Pressure test boiler before attaching water or gas piping (except as noted below) or electrical supply . Prepare boiler for test 1. Remove the shipping nipple (from CGs supply tapping) and remove the boiler relief valve.
P art number 550-110-260/0200 14 GOLD CGs Gas-F ired Water Boiler W ater piping — general information 3a General piping information If installation is to comply with ASME or Canadian requirements, an additional high temperature limit is needed. Install control in supply piping between boiler and isolation valve.
P art number 550-110-260/0200 15 Boiler Manual W ater piping — single -zone system 3b Expansion tank Diaphragm-type or bladder-type expansion tank — Figure 4 1. Ensure expansion tank size will handle boiler and system water v olume and temperature.
P art number 550-110-260/0200 16 GOLD CGs Gas-F ired Water Boiler W ater piping — multiple zones 3c Piping for radiant heating systems or converted gravity systems Converted gravity (or steam) systems Whenever possible, use the primary/secondary piping shown in Figures 8 or 9 on page 19.
P art number 550-110-260/0200 17 Boiler Manual typical piping — multiple -zone installations Figure 6 Zoning with circulators — return water 130 °F or higher .
P art number 550-110-260/0200 18 GOLD CGs Gas-F ired Water Boiler 1. Set the valves while the system is cool, setting for the coldest expected water temperature (usually 60 °F since the system will often drop to room temperature between cycles). 2. Start with valve 7a fully closed and 7b fully open.
P art number 550-110-260/0200 19 Boiler Manual primary/secondary (preferred) bypass piping — for radiant heating or converted gravity systems 1 Boiler isolation (balancing) valves 2 Flow/check valve.
P art number 550-110-260/0200 20 GOLD CGs Gas-F ired Water Boiler W ater piping — low temp systems 3e This piping method is called a boiler -bypass because part of the circulator flo w is bypassed around the boiler (through valve 7a ).
P art number 550-110-260/0200 21 Boiler Manual 1 Boiler isolation (balancing) valves 2 Flow/check valve 3 System or zone circulator 4 System temperature gauges 5 Zone valve 6 Drain valve 7 System temp.
P art number 550-110-260/0200 22 GOLD CGs Gas-F ired Water Boiler W ater piping — low temp systems 3f 1. Start with valve 7a fully closed and 7b fully open. 2. Gradually open valve 7a while closing valve 7b until the temperature at gauge 8 reads at least 130 °F at all times.
P art number 550-110-260/0200 23 Boiler Manual 3 System or zone circulator 7 System temperature valves (see instructions to the left for adjusting valves) 8 Blend temperature gauge 9 Relief valve 10 A utomatic air ve nt (with diap hragm-t ype expansion tank), or connect to tank fitting (closed-type expansion tank).
P art number 550-110-260/0200 24 GOLD CGs Gas-F ired Water Boiler Gas piping 5 Connecting gas supply piping to boiler Figure 14 Gas supply piping V enting and combustion air 4 CGs Boiler must be vented and supplied with combustion and ventilation air as described in W eil-McLain CGs V enting Supplements pa cked in en velope assembly with boiler .
P art number 550-110-260/0200 25 Boiler Manual T able 4 Pipe capacity for 0.60 specific gravity natural gas Gas piping continued 5 Natural Gas: 1. Refer t o T able 4 for pipe length and diamete r . Base on rated boiler input (divide by 1,000 to obtain cubic feet per hour).
P art number 550-110-260/0200 26 GOLD CGs Gas-F ired Water Boiler Figure 15 Field wiring connections — service switch and thermostat (or end switch) provided by installer Fo r your safety , tur n of f electrical power supply at service entrance panel befor e making an y electrical connections to avoid possible electric shock hazard.
P art number 550-110-260/0200 27 Boiler Manual Determine if water treatment is needed Do not use petroleum-based cleaning or sealing compounds in boiler system. Severe damage to boiler will o ccur , res ulting in substant ial pro per ty damage. Eliminate all system leaks.
P art number 550-110-260/0200 28 GOLD CGs Gas-F ired Water Boiler Start -up — operate boiler 7b Inspect system water piping After filling the boiler and system with water , inspect all piping throughout the system for leaks. If found, repair immediately .
P art number 550-110-260/0200 29 Boiler Manual 4. Check around the boiler for gas odor following the procedure of section 7a of this manual. Start -up — operate boiler continued 7b Figure 16 T ypica.
P art number 550-110-260/0200 30 GOLD CGs Gas-F ired Water Boiler Check - out procedure — checklist 8 ❏ Boiler and heat distribution units filled with water? ❏ A utomatic air v ent, if used, ope.
P art number 550-110-260/0200 31 Boiler Manual Operation — sequence 9a Figure 18 Control module sequence of operation — status light indications 1. Read Lighting instr uctions on page 34. T his information is also located on a label on the inside of the boiler jacket door panel.
P art number 550-110-260/0200 32 GOLD CGs Gas-F ired Water Boiler Operation — wiring diagrams 9b Figure 19 Schematic wiring diagram.
P art number 550-110-260/0200 33 Boiler Manual Figure 20 Ladder wiring diagram 71033 1. All w iring must be installed in accor dance with: A. U .S.A. — N.E.C. And an y other national, stat e, or local code requir ements. B. Canada — C.S.A. C22.1 C.
P art number 550-110-260/0200 34 GOLD CGs Gas-F ired Water Boiler Operation — lighting instructions 9c Figure 21 Lighting instructions FOR YOUR SAFETY READ BEFORE OPERA TING OPERA TING INSTRUCTIONS TO TURN OFF GAS TO THE APPLIANCE • Do not try to light any appliance.
P art number 550-110-260/0200 35 Boiler Manual T able 5 Service and maintenance schedules Service and maintenance — schedule 10a Follow the Service and maintenance procedures given throughout this manual and in compon ent literature shipped with the boiler .
P art number 550-110-260/0200 36 GOLD CGs Gas-F ired Water Boiler Service & maintenance — annual start -up 10b The boiler should be inspected and star ted annually , at the beginning of the heating season, only b y a qualified service te chnician .
P art number 550-110-260/0200 37 Boiler Manual ❏ Service . . . . . . . . . . ❏ Inspect . . . . . . . . . . Inducer motor 1. W ith boiler power OFF , plac e a few drops o f S.A.E. 20 motor oil in each of the two oil cups. Use on ly S.A.E. 20 motor oil to lubricate the induc er motor .
P art number 550-110-260/0200 38 GOLD CGs Gas-F ired Water Boiler Service & maint. — annual start -up continued 10b ❏ Start-up . . . . . . . . . 1 . Start the b oiler , follo w ing the instruct ions in manual section 7 . 2. V erify cold fill pressur e is correct and that fill system is w orking properly .
P art number 550-110-260/0200 39 Boiler Manual 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.
P art number 550-110-260/0200 40 GOLD CGs Gas-F ired Water Boiler 1. Review the User’ s Infor mation Manual with the owner . 2. Emphasize the need to perf orm the maintenance schedule specified in the User’ s Infor mation Manual (and in this manual as well).
P art number 550-110-260/0200 41 Boiler Manual T roubleshooting — procedure 11a Label all wires prior to disconnection when se r vicing controls. Wiring errors can cause improper and dangerous operation. Never jumper (bypass) rollout thermal fuse element or any other device ex cept for momentar y testing as outlined in T roubleshooting Char ts .
P art number 550-110-260/0200 42 GOLD CGs Gas-F ired Water Boiler T roubleshooting — air pressure switch 11b Make sure boiler water temperature is 100 °F or cooler before starting procedure to obtain appropriate readings. Check pressure switch setting 1.
P art number 550-110-260/0200 43 Boiler Manual T roubleshooting — control module 11c 26036 Make sure ground wir ing is installed per wiring diagram. Good grounding is extremely important for proper operation.
P art number 550-110-260/0200 44 GOLD CGs Gas-F ired Water Boiler T roubleshooting — control module continued 11c Figure 25 Control module connections Indicator lights POWER TST A T CIRC LIMIT PRESS.
P art number 550-110-260/0200 45 Boiler Manual T roubleshooting — control module lights 11d CHART 1 — Troubleshootin g POWER light status Electrical shock h azard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions. Fai lure to follow instructions could result in severe personal injury, death or substantial pro perty damage.
P art number 550-110-260/0200 46 GOLD CGs Gas-F ired Water Boiler T roubleshooting — control module lights 11d Electrical shock hazard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions. Failure to fo llow instructions could result in severe personal injury, death or substantial pro perty damage.
P art number 550-110-260/0200 47 Boiler Manual continued CHART 3 — PRESS SWITCH & POWER lights flashing Electrical shock hazard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions. Failure to fo llow instructions could result in severe personal injury, death or substantial pro perty damage.
P art number 550-110-260/0200 48 GOLD CGs Gas-F ired Water Boiler T roubleshooting — control module lights 11d • Turn off power to the boiler at service switch or breake r. • Wait at least 45 seconds. • Turn on power to boiler. • Restart boiler, following Lighting instructions in this manual ( Figure 21 , page 34).
P art number 550-110-260/0200 49 Boiler Manual continued • ▲ TURN OFF POWER ▲ to boiler at service switch or breaker. • Remove air inlet box cover (see Figure 27 , page 54 for location) . • Verify inlet gas pressure at gas valve: Natural gas — 5.
P art number 550-110-260/0200 50 GOLD CGs Gas-F ired Water Boiler T roubleshooting — control module lights 11d CHART 6 — PRESS SWITCH light flashing and POWER light on steady Electrical shock hazard — Wherever you see ▲ TURN OFF POWER ▲ , follow the instructions.
P art number 550-110-260/0200 51 Boiler Manual continued 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 fo llow instructions could result in severe personal injury, death or substantial pro perty damage.
P art number 550-110-260/0200 52 GOLD CGs Gas-F ired Water Boiler Replacement parts 12a Section assembly ................................................ 53 Base assembly .................................................... 54 Jack et assembly .......
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P art number 550-110-260/0200 58 GOLD CGs Gas-F ired Water Boiler Dimensions 13a Figure 31 Dimensional drawing T OP VIE W 19 19 13¹¹₁₆ 28³⁄₈ 1⁵⁄₈ 4³⁄₄ 4³⁄₄ 13¹⁄₄ 11.
P art number 550-110-260/0200 59 Boiler Manual Ratings T able 7 Boiler ratings DOE 1 . A dd “PIN” for natural gas boiler - “PIL ” f or propane gas boiler . 2. Based on standard test procedures prescribed by the U nited States Department of Energy .
60 P art Number 550-110-260/0200 GOLD CGs Gas-F ired Water Boiler — Boiler Man ual W eil-McLain 500 Blaine Street Michigan City , IN 46360-2388 http://www .
An important point after buying a device Weil-McLain GOLD CGS 550-110-260/02002 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Weil-McLain GOLD CGS 550-110-260/02002 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Weil-McLain GOLD CGS 550-110-260/02002 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Weil-McLain GOLD CGS 550-110-260/02002 you will learn all the available features of the product, as well as information on its operation. The information that you get Weil-McLain GOLD CGS 550-110-260/02002 will certainly help you make a decision on the purchase.
If you already are a holder of Weil-McLain GOLD CGS 550-110-260/02002, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Weil-McLain GOLD CGS 550-110-260/02002.
However, one of the most important roles played by the user manual is to help in solving problems with Weil-McLain GOLD CGS 550-110-260/02002. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Weil-McLain GOLD CGS 550-110-260/02002 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
