Weil-McLain 550-110-260/0107 2a Prepare boiler placement & setup, Inspect orifices and burners

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GOLD CGs Gas-Fired Water Boiler — Boiler Manual

2a Prepare boiler — placement & setup

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 loca- tion.

3.Remove crate.

4.Remove boiler from pallet.

Do not drop boiler or bump jacket on floor or pallet. Damage to boiler can result.

a.Tilt left side of boiler up and place a board under left legs.

b.Tilt boiler the other way and place a board under right legs.

c.Slide boiler backward off pallet and into posi- tion.

5.Check level.

a.Shim legs, if necessary.

b.Do not alter legs.

Inspect orifices and burners

1.Remove front jacket door. Remove inlet air box top panel (see Figure 27, item 13, page 56).

2.Check for correctly-sized manifold orifices. See Table 2 for sizing. (The orifice size is stamped on the orifice spud barrel.)

Correctly-sized manifold orifices must be used. Failure to do so will result in severe personal injury, death or substantial property dam- age.

3. Reinstall inlet air box top panel.

Inlet air box top panel must be in position during boiler operation. Failure to do so could result in severe personal injury, death or substantial property damage.

Orifice replacement procedure

(when required)

1.Remove the screws securing the inlet air box top panel.

2.Remove inlet air box top panel and inspect the fiber gasket.Verify the gasket is in good condition and can seal around the complete perimeter of the air box. Replace the gasket if necessary.

3.Using a 7/16” open-end wrench, remove the burner orifices from the manifold.

4.Apply a small amount of pipe dope to each of the new orifices and install in the manifold using a 7/16” open-end wrench. Make sure the orifices are aligned correctly, not cross-threaded in the manifold tap- pings.

Use only pipe dope compatible with propane gas, even if boiler is to be operated on natural gas. Failure to comply could result in severe per- sonal injury, death or substantial property damage.

5.Carefully replace the inlet air box top panel, making sure the gasket is in place will seal all around the perimeter.

6.Follow the check-out procedure, Section 8 page 30, to assure the boiler is now operating properly after

Table 2  Manifold orifice sizing

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Part number 550-110-260/0107

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Contents Gold CGs How it works Gold CGs Gas-Fired Induced-Draft Water Boiler Contents Installer Please read before proceedingUser 1a Prepare boiler location codes & checklist Installations must follow these codesBefore locating the boiler, check the following 1b Prepare boiler location clearances When removing boiler from an existing common vent system 1c Prepare boiler location vent systemCGs special vent system Vent system1d Prepare boiler location contamination Products to avoid1e Prepare boiler location air openings Combustion air optionsSpecial considerations Sizing air openingsSizing air openings for CGs installations 2a Prepare boiler placement & setup Orifice replacement procedurePlace boiler/crate near position Inspect orifices and burners2b Prepare boiler pressure test Hydrostatic pressure testDrain and remove fittings Prepare boiler for test3a Water piping general information 3b Water piping single-zone system 3c Water piping multiple zones Piping multiple zones Piping for radiant heatingSystems or converted gravity SystemsReturn water 130F or higher Temperature gauges Valve adjustment Figures 8 and 9 only3d Piping low temp systems Primary/secondary preferred bypass piping methodPrimary/secondary piping Valve adjustment BOILER-bypass piping methodFigures 8 SYSTEM-bypass piping method 3e Water piping refrigeration systems Prevent chilled water from enteringVenting and combustion air Connecting gas supply piping to boiler Gas pipingNatural Gas Propane GasField wiring Electrical installation must comply withWiring connections ThermostatFreeze protection when used 7a Start-up preparationCheck for gas leaks Verify water chemistry7b Start-up operate boiler Inspect system water piping Inspect base insulationFinal check before starting boiler Start the boiler7c Start-up if boiler doesn’t start Check burner flamesCheck for Pilot burner flame FigureCheck-out procedure checklist Installation and service certificate9a Operation sequence 9b Operation wiring diagrams Schematic wiring diagramLadder wiring diagram 9c Operating instructions CGs-3 to CGs-6 9c Operating instructions CGs-3 to CGs-6 9c Operating instructions CGs-3 to CGi-6 10a Service and maintenance schedule Verify Proper Operation After Servicing10b Service & maintenance annual start-up Burners, base and inlet air box Condensate drain systemInducer motor Oiled-bearing circulators10b Service & maint. annual start-up Boiler relief valve Relief valve, typicalCleaning boiler heating surfaces Review with owner11a Troubleshooting procedure Before troubleshootingCheck the following 11b Troubleshooting air pressure switch Air pressure switchCheck pressure switch setting Troubleshooting air pressure reading11c Troubleshooting control module Control indicator lights Lockout modesControl indicator lights NON-LOCKOUT modes Troubleshooting the control moduleControl module connections 11d Troubleshooting control module lights Chart 1 Troubleshooting Power light statusChart 2 Tstat Circ & Power lights flashing Chart 3 Press Switch & Power lights flashing Chart 4 Flame & Power lights flashing Item 8 , Does blower motor operate? Verify Sequence of operation, , 12a Replacement parts Section assembly Base Jacket Trim Controls12b Replacement parts section assembly Section assembly12c Replacement parts base Base assemblyDescription Weil-McLain Part number 12d Replacement parts jacket Jacket assemblyBoiler Model Weil-McLain part number 12e Replacement parts trim Part number12f Replacement parts controls Propane gas components13a Dimensions Dimensional drawing13b Ratings DOEHandling ceramic fiber and fiberglass materials Removal of Combustion Chamber Lining or Base Panels
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