Weil-McLain 550-110-260/0107 Field wiring, Thermostat, Electrical installation must comply with

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GOLD CGs Gas-Fired Water Boiler — Boiler Manual

6 Field wiring

For your safety, turn off electrical power supply at service entrance panel before making any electrical

connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death.

Wiring must be N.E.C. Class 1.

If original wiring as supplied with boiler must be re- placed, use only type 105°C wire or equivalent.

Boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 70 – latest edi- tion.

Thermostat

1.Connect thermostat as shown on wiring diagram on boiler.

2.Install on inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, television, sunrays, or fireplaces.

3.If thermostat has a heat anticipator, set heat antici- pator in thermostat to match power requirements of equipment connected to it. If connected directly to boiler, set for 0.4 amps. For other devices, refer to manufacturer’s specifications. Wiring diagram on boiler gives setting for control module and gas valve. Also see instructions with thermostat.

Electrical installation must comply with:

1.National Electrical Code and any other national, state, provincial or local codes or regulations.

2.In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes.

Wiring connections

Boiler is shipped with controls completely wired.

Junction Box (furnished)

1.Connect 120 VAC power wiring as shown in

Figure 15.

2.Fused disconnect or service switch (15 amp. recom- mended) may be mounted on this box. For those installations with local codes which prohibit installa- tion of fused disconnect or service switch on boiler, install a 2 x 4 cover plate on the boiler junction box and mount the service switch remotely as required by the code.

The CGs control module is polarity-sensitive. The hot and neutral wires must be connected to the correct leads. A flashing POWER light usually indicates reversed polarity of 120 VAC lead wires.

Figure 15 Field wiring connections — service switch and thermostat (or end switch) provided by installer

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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 User InstallerPlease read before proceeding Before locating the boiler, check the following 1a Prepare boiler location codes & checklistInstallations must follow these codes 1b Prepare boiler location clearances CGs special vent system When removing boiler from an existing common vent system1c Prepare boiler location vent system Vent system1d Prepare boiler location contamination Products to avoidSpecial considerations 1e Prepare boiler location air openingsCombustion air options Sizing air openingsSizing air openings for CGs installations Place boiler/crate near position 2a Prepare boiler placement & setupOrifice replacement procedure Inspect orifices and burnersDrain and remove fittings 2b Prepare boiler pressure testHydrostatic pressure test Prepare boiler for test3a Water piping general information 3b Water piping single-zone system Systems or converted gravity 3c Water piping multiple zonesPiping multiple zones Piping for radiant heating SystemsReturn water 130F or higher 3d Piping low temp systems Temperature gaugesValve adjustment Figures 8 and 9 only 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 Natural Gas Connecting gas supply piping to boilerGas piping Propane GasWiring connections Field wiringElectrical installation must comply with ThermostatCheck for gas leaks Freeze protection when used7a Start-up preparation Verify water chemistryFinal check before starting boiler 7b Start-up operate boilerInspect system water piping Inspect base insulation Start the boilerCheck for 7c Start-up if boiler doesn’t startCheck burner flames 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 Inducer motor Burners, base and inlet air boxCondensate drain system Oiled-bearing circulators10b Service & maint. annual start-up Boiler relief valve Relief valve, typicalCleaning boiler heating surfaces Review with ownerCheck the following 11a Troubleshooting procedureBefore troubleshooting Check pressure switch setting 11b Troubleshooting air pressure switchAir pressure switch Troubleshooting air pressure readingControl indicator lights NON-LOCKOUT modes 11c Troubleshooting control moduleControl indicator lights 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