Weil-McLain 550-110-260/0107 manual 1a Prepare boiler location codes & checklist

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GOLD CGs Gas-Fired Water Boiler — Boiler Manual

1a 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.

•National Electrical Code.

•For Canada only: B149.1 or B149.2 Installation Code, CSA C22.1 Canadian Electri- cal Code Part 1 and any local codes.

The CGs boiler gas manifold and controls met safe lighting and other performance criteria when boiler underwent tests specified in ANSI Z21.13–latest edition.

Before locating the boiler, check the following:

•Check for nearby connection to:

•System water piping

•Venting connections

•Gas supply piping

•Electrical power

•Check area around boiler. Remove any combustible materials, gasoline and other flammable liquids, or other contaminants.

•Check for nearby connection to:

•System water piping

•Venting connections

•Gas supply piping

•Electrical power

•Check area around boiler. Remove any combustible materials, gasoline and other flammable liquids, or other contaminants.

Failure to keep boiler area clear and free of combustible materials, gasoline and other flammable liquids and vapors can result in severe personal injury, death or substantial property damage.

•Boiler must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service.

•If new boiler will replace existing boiler, check for and correct system problems, such as:

1.System leaks causing oxygen corrosion or section cracks from hard water deposits.

2.Incorrectly-sized expansion tank.

3.Lack of antifreeze in boiler water causing system and boiler to freeze and leak.

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 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 owner11a Troubleshooting procedure Before troubleshootingCheck the following 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