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Weil-McLain 550-110-260/0107 manual 10a Service and maintenance - schedule

Models: 550-110-260/0107

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GOLD CGs Gas-Fired Water Boiler — Boiler Manual

10a Service and maintenance — schedule

VERIFY PROPER OPERATION AFTER SERVICING

Table 5 Service and maintenance schedules

Follow the Service and maintenance procedures given throughout this manual and in com- ponent literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death or substantial property damage.

Part number 550-110-260/0107

Page 37

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Weil-McLain 550-110-260/0107 manual 10a Service and maintenance - schedule, Verify Proper Operation After Servicing

Contents

• Startup • Parts Installation MaintenanceGOLD CGs Boiler ManualGOLD CGs Gas-FiredWater Boiler — Boiler Manual How it works④Air pressure switch ⑤Water temperature limit switchGOLD CGs Gas-FiredWater Boiler — Boiler Manual GOLD CGs Gas-Fired Induced-DraftWater BoilerField wiring ContentsCheck-outprocedure Service and maintenancePlease read before proceeding InstallerUser When servicing boiler —Installations must follow these codes 1a Prepare boiler location — codes & checklistBefore locating the boiler, check the following GOLD CGs Gas-FiredWater Boiler - Boiler ManualResidential garage installations Recommended SERVICE clearances1b Prepare boiler location — clearances Required MINIMUM clearances Fig.CGs special vent system 1c Prepare boiler location — vent systemGOLD CGs Gas-FiredWater Boiler — Boiler Manual Vent systemGOLD CGs Gas-FiredWater Boiler — Boiler Manual 1d Prepare boiler location — contaminationCombustion air options 1e Prepare boiler location — air openingsSpecial considerations Sizing air openingsGOLD CGs Gas-FiredWater Boiler — Boiler Manual Orifice replacement procedure 2a Prepare boiler — placement & setupPlace boiler/crate near position Inspect orifices and burnersHydrostatic pressure test 2b Prepare boiler - pressure testDrain and remove fittings GOLD CGs Gas-FiredWater Boiler — Boiler Manual3a Water piping - general information Pressure/temperature gaugeGeneral piping information CirculatorDiaphragm-typeor bladder 3b Water piping — single-zonesystemClosed-typeexpansion tank type expansion tank FigurePiping multiple zones 3c Water piping — multiple zonesPiping for radiant heating systems or converted gravityGOLD CGs Gas-FiredWater Boiler — Boiler Manual 3c Water piping - multiple zones continuedPrimary/secondary preferred bypass piping method 3d Piping — low temp systemsTemperature gauges Valve adjustment Figures 8 and 9 onlyGOLD CGs Gas-FiredWater Boiler — Boiler Manual 3d Piping — low temp systems continuedTemperature gauges BOILER-bypasspiping methodValve adjustment 3d Piping — low temp systems continuedGOLD CGs Gas-FiredWater Boiler — Boiler Manual 3d Piping - low temp systems continued1Boiler isolation balancing valves Valve adjustment SYSTEM-bypasspiping method3d Piping — low temp systems continued GOLD CGs Gas-FiredWater Boiler — Boiler Manual3d Piping — low temp systems continued 3e Water piping — refrigeration systemsGOLD CGs Gas-FiredWater Boiler — Boiler Manual Prevent chilled water from enteringGOLD CGs Gas-FiredWater Boiler — Boiler Manual 4 Venting and combustion air5 Gas piping Connecting gas supply piping to boilerNatural Gas Propane GasElectrical installation must comply with 6 Field wiringWiring connections Thermostat7a Start-up— preparation Freeze protection when usedDetermine if water treatment is needed Fill the system with water7b Start-up— operate boiler 7a Start-up— preparation continuedFinal check before starting boiler Start the boiler7c Start-up- if boiler doesn’t start 7b Start-up— operate boiler continuedCheck burner flames Check forInstallation and service certificate 8 Check-outprocedure — checklistGOLD CGs Gas-FiredWater Boiler — Boiler Manual GOLD CGs Gas-FiredWater Boiler — Boiler Manual 9a Operation — sequenceFigure 19 Schematic wiring diagram 9b Operation — wiring diagramsGOLD CGs Gas-FiredWater Boiler — Boiler Manual GOLD CGs Gas-FiredWater Boiler - Boiler Manual Figure 20 Ladder wiring diagramGOLD CGs Gas-FiredWater Boiler — Boiler Manual 9c Operating instructions CGs-3to CGs-6• Spark pilot • Natural or propane gas • Gas valve: Honeywell VR8204/VR8304GOLD CGs Gas-FiredWater Boiler — Boiler Manual 9c Operating instructions CGs-3to CGs-6• Spark pilot • Natural or propane gas • Gas valve: White-Rodgers36EGOLD CGs Gas-FiredWater Boiler — Boiler Manual 9c Operating instructions CGs-3to CGi-6• Spark pilot • Natural or propane gas Gas valve White-Rodgers36CVERIFY PROPER OPERATION AFTER SERVICING 10a Service and maintenance - scheduleGOLD CGs Gas-FiredWater Boiler — Boiler Manual Inspect 10b Service & maintenance — annual start-upReported problems GOLD CGs Gas-FiredWater Boiler — Boiler ManualStart-up ServiceInspect GOLD CGs Gas-FiredWater Boiler — Boiler ManualCheck/test 10b Service & maint. — annual start-up continuedGOLD CGs Gas-FiredWater Boiler — Boiler Manual Gas pipingBoiler relief valve GOLD CGs Gas-FiredWater Boiler — Boiler ManualCleaning boiler heating surfaces 10b Service & maint. — annual start-upReview with owner GOLD CGs Gas-FiredWater Boiler - Boiler ManualBefore troubleshooting 11a Troubleshooting — procedureCheck the following GOLD CGs Gas-FiredWater Boiler — Boiler ManualAir pressure switch 11b Troubleshooting — air pressure switchReturn to normal operation Check pressure switch settingControl module 11c Troubleshooting — control moduleControl indicator lights — LOCKOUT modes Control indicator lights — NON-LOCKOUTmodesGOLD CGs Gas-FiredWater Boiler — Boiler Manual 11c Troubleshooting — control module continuedFigure 25 Control module connections CHART 1 — Troubleshooting POWER light status 11d Troubleshooting — control module lightsIs POWER light off? Is POWER light11d Troubleshooting — control module lights CHART 2 — TSTAT CIRC & POWER lights flashingDo the TSTAT and POWER lights still flash? GOLD CGs Gas-FiredWater Boiler — Boiler ManualCHART 3 — PRESS SWITCH & POWER lights flashing 11d Troubleshooting — control module lights contIs PRESS SWITCH light flashing? Does the ohmmeter indicate the switch is closed?Do FLAME and POWER lights still flash? 11d Troubleshooting — control module lights contAre FLAME & POWER lights flashing? Are FLAME and POWER lights flashing?TURN OFF POWER 11d Troubleshooting — control module lights contTURN OFF POWER TURN OFF POWER toDoes the ohmmeter indicate the switch is closed? 11d Troubleshooting — control module lights contGOLD CGs Gas-FiredWater Boiler — Boiler Manual Does blower motor operate?Does voltmeter show 120 VAC across pins? 11d Troubleshooting — control module lights contAre limit switch contacts closed? continuity — is switchSection assembly 12a Replacement partsBase 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 GOLD CGs Gas-FiredWater Boiler — Boiler Manual 12c Replacement parts — base continuedDescription Weil-McLainFigure 28 Jacket assembly 12d Replacement parts — jacketGOLD CGs Gas-FiredWater Boiler — Boiler Manual GOLD CGs Gas-FiredWater Boiler — Boiler Manual 12d Replacement parts — jacket continuedFittings shown are factory-installedon boiler 12e Replacement parts — trimGOLD CGs Gas-FiredWater Boiler — Boiler Manual 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 GOLD CGs Gas-FiredWater Boiler — Boiler Manual 13b RatingsGOLD CGs Gas-FiredWater Boiler — Boiler Manual Handling ceramic fiber and fiberglass materialsREMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS