Manuals / Weil-McLain / Household Appliance / Boiler

Weil-McLain 550-110-260/0107 manual 9c Operating instructions CGs-3to CGs-6

Models: 550-110-260/0107

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GOLD CGs Gas-Fired Water Boiler — Boiler Manual

9c Operating instructions CGs-3 to CGs-6

• Spark pilot • Natural or propane gas

• Gas valve: Honeywell VR8204/VR8304

Part number 550-110-260/0107

Page 34

Image 34

Weil-McLain 550-110-260/0107 manual 9c Operating instructions CGs-3to CGs-6, GOLD CGs Gas-FiredWater Boiler — Boiler Manual

Contents

GOLD CGs Installation Maintenance• Startup • Parts Boiler Manual④Air pressure switch How it worksGOLD CGs Gas-FiredWater Boiler — Boiler Manual ⑤Water temperature limit switchGOLD CGs Gas-Fired Induced-DraftWater Boiler GOLD CGs Gas-FiredWater Boiler — Boiler ManualCheck-outprocedure ContentsField wiring Service and maintenanceUser InstallerPlease read before proceeding When servicing boiler —Before locating the boiler, check the following 1a Prepare boiler location — codes & checklistInstallations must follow these codes GOLD CGs Gas-FiredWater Boiler - Boiler Manual1b Prepare boiler location — clearances Recommended SERVICE clearancesResidential garage installations Required MINIMUM clearances Fig.GOLD CGs Gas-FiredWater Boiler — Boiler Manual 1c Prepare boiler location — vent systemCGs special vent system Vent system1d Prepare boiler location — contamination GOLD CGs Gas-FiredWater Boiler — Boiler ManualSpecial considerations 1e Prepare boiler location — air openingsCombustion air options Sizing air openingsGOLD CGs Gas-FiredWater Boiler — Boiler Manual 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 GOLD CGs Gas-FiredWater Boiler — Boiler ManualGeneral piping information Pressure/temperature gauge3a Water piping - general information CirculatorClosed-typeexpansion tank 3b Water piping — single-zonesystemDiaphragm-typeor bladder type expansion tank FigurePiping for radiant heating 3c Water piping — multiple zonesPiping multiple zones systems or converted gravity3c Water piping - multiple zones continued GOLD CGs Gas-FiredWater Boiler — Boiler ManualTemperature gauges 3d Piping — low temp systemsPrimary/secondary preferred bypass piping method Valve adjustment Figures 8 and 9 only3d Piping — low temp systems continued GOLD CGs Gas-FiredWater Boiler — Boiler ManualValve adjustment BOILER-bypasspiping methodTemperature gauges 3d Piping — low temp systems continuedGOLD CGs Gas-FiredWater Boiler — Boiler Manual 3d Piping - low temp systems continued1Boiler isolation balancing valves 3d Piping — low temp systems continued SYSTEM-bypasspiping methodValve adjustment GOLD CGs Gas-FiredWater Boiler — Boiler ManualGOLD CGs Gas-FiredWater Boiler — Boiler Manual 3e Water piping — refrigeration systems3d Piping — low temp systems continued Prevent chilled water from entering4 Venting and combustion air GOLD CGs Gas-FiredWater Boiler — Boiler ManualNatural Gas Connecting gas supply piping to boiler5 Gas piping Propane GasWiring connections 6 Field wiringElectrical installation must comply with ThermostatDetermine if water treatment is needed Freeze protection when used7a Start-up— preparation Fill the system with waterFinal check before starting boiler 7a Start-up— preparation continued7b Start-up— operate boiler Start the boilerCheck burner flames 7b Start-up— operate boiler continued7c Start-up- if boiler doesn’t start Check forInstallation and service certificate 8 Check-outprocedure — checklistGOLD CGs Gas-FiredWater Boiler — Boiler Manual 9a Operation — sequence GOLD CGs Gas-FiredWater Boiler — Boiler ManualFigure 19 Schematic wiring diagram 9b Operation — wiring diagramsGOLD CGs Gas-FiredWater Boiler — Boiler Manual Figure 20 Ladder wiring diagram GOLD CGs Gas-FiredWater Boiler - Boiler Manual• Spark pilot • Natural or propane gas 9c Operating instructions CGs-3to CGs-6GOLD CGs Gas-FiredWater Boiler — Boiler Manual • Gas valve: Honeywell VR8204/VR8304• Spark pilot • Natural or propane gas 9c Operating instructions CGs-3to CGs-6GOLD CGs Gas-FiredWater Boiler — Boiler Manual • Gas valve: White-Rodgers36E• Spark pilot • Natural or propane gas 9c Operating instructions CGs-3to CGi-6GOLD CGs Gas-FiredWater Boiler — Boiler Manual Gas valve White-Rodgers36CVERIFY PROPER OPERATION AFTER SERVICING 10a Service and maintenance - scheduleGOLD CGs Gas-FiredWater Boiler — Boiler Manual Reported problems 10b Service & maintenance — annual start-upInspect GOLD CGs Gas-FiredWater Boiler — Boiler ManualInspect ServiceStart-up GOLD CGs Gas-FiredWater Boiler — Boiler ManualGOLD CGs Gas-FiredWater Boiler — Boiler Manual 10b Service & maint. — annual start-up continuedCheck/test Gas pipingGOLD CGs Gas-FiredWater Boiler — Boiler Manual Boiler relief valveReview with owner 10b Service & maint. — annual start-upCleaning boiler heating surfaces GOLD CGs Gas-FiredWater Boiler - Boiler ManualCheck the following 11a Troubleshooting — procedureBefore troubleshooting GOLD CGs Gas-FiredWater Boiler — Boiler ManualReturn to normal operation 11b Troubleshooting — air pressure switchAir pressure switch Check pressure switch settingControl indicator lights — LOCKOUT modes 11c Troubleshooting — control moduleControl module Control indicator lights — NON-LOCKOUTmodesGOLD CGs Gas-FiredWater Boiler — Boiler Manual 11c Troubleshooting — control module continuedFigure 25 Control module connections Is POWER light off? 11d Troubleshooting — control module lightsCHART 1 — Troubleshooting POWER light status Is POWER lightDo the TSTAT and POWER lights still flash? CHART 2 — TSTAT CIRC & POWER lights flashing11d Troubleshooting — control module lights GOLD CGs Gas-FiredWater Boiler — Boiler ManualIs PRESS SWITCH light flashing? 11d Troubleshooting — control module lights contCHART 3 — PRESS SWITCH & POWER lights flashing Does the ohmmeter indicate the switch is closed?Are FLAME & POWER lights flashing? 11d Troubleshooting — control module lights contDo FLAME and POWER lights still flash? Are FLAME and POWER lights flashing?TURN OFF POWER 11d Troubleshooting — control module lights contTURN OFF POWER TURN OFF POWER toGOLD CGs Gas-FiredWater Boiler — Boiler Manual 11d Troubleshooting — control module lights contDoes the ohmmeter indicate the switch is closed? Does blower motor operate?Are limit switch contacts closed? 11d Troubleshooting — control module lights contDoes voltmeter show 120 VAC across pins? continuity — is switchBase 12a Replacement partsSection assembly JacketFigure 26 Section assembly 12b Replacement parts — section assemblyGOLD CGs Gas-FiredWater Boiler — Boiler Manual Figure 27 Base assembly 12c Replacement parts — baseGOLD CGs Gas-FiredWater Boiler — Boiler Manual Description 12c Replacement parts — base continuedGOLD CGs Gas-FiredWater Boiler — Boiler Manual Weil-McLainFigure 28 Jacket assembly 12d Replacement parts — jacketGOLD CGs Gas-FiredWater Boiler — Boiler Manual 12d Replacement parts — jacket continued GOLD CGs Gas-FiredWater Boiler — Boiler ManualGOLD CGs Gas-FiredWater Boiler — Boiler Manual 12e Replacement parts — trimFittings shown are factory-installedon boiler ItemFigure 30 Gas control assembly 12f Replacement parts — controlsGOLD CGs Gas-FiredWater Boiler - Boiler Manual Figure 31 Dimensional drawing 13a DimensionsGOLD CGs Gas-FiredWater Boiler — Boiler Manual 13b Ratings GOLD CGs Gas-FiredWater Boiler — Boiler ManualREMOVAL OF COMBUSTION CHAMBER Handling ceramic fiber and fiberglass materialsGOLD CGs Gas-FiredWater Boiler — Boiler Manual LINING OR BASE PANELS