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550-110-260/02002 9b Operation — wiring diagrams, GOLD CGs Gas-FiredWater Boiler
Models:
550-110-260/02002
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Troubleshooting
Install
Error codes
9b Operation — wiring diagrams
2a Prepare boiler — placement & setup
Dimension
Maintenance
Connecting gas supply piping to boiler
Reported problems
Section assembly
Page 32
Image 32
GOLD
CGs
Gas-Fired
Water Boiler
9b
Operation —
wiring diagrams
Figure 19
Schematic wiring diagram
32
Part number
550-110-260/0200
Page 31
Page 33
Page 32
Image 32
Page 31
Page 33
Contents
Page
How it works
GOLD CGs Gas-FiredWater Boiler
Page
Contents
12. Replacement parts
6–11
3. Water piping
Installer
Please read before proceeding
Boiler Manual
User
1a Prepare boiler location — codes & checklist
Installations must follow these codes
GOLD CGs Gas-FiredWater Boiler
Before locating the boiler, check the following
Residential garage installation
1b Prepare boiler location — clearances
Flooring and foundation
Provide the following clearances
1c Prepare boiler location — vent system
Removing from existing vent
CGs special vent system
GOLD CGs Gas-FiredWater Boiler
1d Prepare boiler location — contamination
Air contamination
Boiler Manual
Table 1 Corrosive contaminants
1e Prepare boiler location — air openings
CGs combustion air options
Sizing air openings
Special considerations
Direct exhaust vent installation
Direct vent installation
Boiler Manual
Room Air Openings
2a Prepare boiler — placement & setup
Orifice replacement procedure
Place boiler/crate near position
Inspect orifices and burners
2b Prepare boiler — pressure test
Perform hydrostatic pressure test
Boiler Manual
Prepare boiler for test
Pressure/temperature gauge
3a Water piping — general information
General piping information
Circulator
3b Water piping — single-zonesystem
Expansion tank
Boiler Manual
Closed-typeexpansion tank - Figure
3c Water piping — multiple zones
Zoning with zone valves, return temp over 130 F
Zoning with circulators, return temp over 130 F
GOLD CGs Gas-FiredWater Boiler
typical piping — multiple-zoneinstallations
Boiler Manual
Zoning with circulators
— return water 130 F or higher
Temperature gauges Valve adjustment
3d Water piping — low temp systems
Primary/secondary preferred bypass piping method
GOLD CGs Gas-FiredWater Boiler
primary/secondary preferred bypass piping
for radiant heating or converted gravity systems
Boiler Manual
Figure
3e Water piping - low temp systems
Temperature gauges Valve adjustment
GOLD CGs Gas-FiredWater Boiler
Boiler-bypasspiping method
boiler-bypassalternate piping —
Boiler Manual
for radiant heating or converted gravity systems
Figure 10 Boiler-bypasspiping
Valve adjustment
3f Water piping - low temp systems
GOLD CGs Gas-FiredWater Boiler
System-bypasspiping method
3f system-bypassalternate piping —
3g Water piping — refrigeration system
for converted gravity or steam systems
Prevent chilled water from entering boiler
Connecting gas supply piping to boiler
4Venting and combustion air
5Gas piping
GOLD CGs Gas-FiredWater Boiler
Natural Gas
5 Gas piping continued
Boiler Manual
6Field wiring
Wiring connections
Electrical installation must comply with
GOLD CGs Gas-FiredWater Boiler
7a Start-up— preparation
Determine if water treatment is needed
Check for gas leaks
Fill the system with water
7a Start-up— preparation continued
7b Start-up- operate boiler
Inspect system water piping
Final check before starting boiler
7b Start-up— operate boiler continued
7c Start-up— if boiler doesn’t start
Check burner flames
Check for
GOLD CGs Gas-FiredWater Boiler
8Check-outprocedure — checklist
Installation and service certificate
9a Operation — sequence
Boiler Manual
GOLD CGs Gas-FiredWater Boiler
9b Operation — wiring diagrams
Figure 19 Schematic wiring diagram
Legend for ladder wiring diagram
G Power
R Press switch
Boiler Manual
FOR YOUR SAFETY READ BEFORE OPERATING
9c Operation - lighting instructions
OPERATING INSTRUCTIONS
TO TURN OFF GAS TO THE APPLIANCE
10a Service and maintenance — schedule
Service technician
Owner maintenance
Table 5 Service and maintenance schedules
10b Service & maintenance — annual start-up
Inspect
Reported problems
GOLD CGs Gas-FiredWater Boiler
Service
Inspect
Boiler Manual
Burners, base and inlet air box
10b Service & maint. — annual start-up continued
Start-up
Check/test
GOLD CGs Gas-FiredWater Boiler
Boiler Manual
Boiler relief valve
lever must be operated AT LEAST
Figure 23 Relief valve, typical
10b Service & maint. - annual start-up
Cleaning boiler heating surfaces
Review with owner
GOLD CGs Gas-FiredWater Boiler
11a Troubleshooting — procedure
Before troubleshooting
Check the following
VERIFY PROPER OPERATION AFTER SERVICING
11b Troubleshooting — air pressure switch
Check pressure switch setting
Troubleshooting air pressure reading
Table 6 Pressure switch setpoint
11c Troubleshooting — control module
Control indicator lights — lockout modes
Control indicator lights — non-lockoutmodes
Troubleshooting the control module
11c Troubleshooting — control module continued
GOLD CGs Gas-FiredWater Boiler
Figure 25 Control module connections
120 VAC IN
11d Troubleshooting — control module lights
CHART 1 — Troubleshooting POWER light status
Is POWER light off?
Is POWER light
11d Troubleshooting — control module lights
CHART 2 — TSTAT CIRC & POWER lights flashing
Do the TSTAT and POWER lights still flash?
GOLD CGs Gas-FiredWater Boiler
continued
CHART 3 — PRESS SWITCH & POWER lights flashing
Is PRESS SWITCH light flashing?
Does the ohmmeter indicate the switch is closed?
11d Troubleshooting — control module lights
Do FLAME and POWER lights still flash?
Are FLAME & POWER lights flashing?
Are FLAME and POWER lights flashing?
Natural gas — 5.0 w.c. min/14.0 w.c. max
Boiler Manual
continued
11d Troubleshooting — control module lights
Does the ohmmeter indicate the switch is closed?
Is PRESS SWITCH light flashing?
GOLD CGs Gas-FiredWater Boiler
Does voltmeter show 120 VAC across pins?
Are limit switch contacts closed?
Boiler Manual
continued
12a Replacement parts
Section assembly
Base assembly
Jacket assembly
Page
Page
Page
Page
Page
GOLD CGs Gas-FiredWater Boiler
13a Dimensions
Figure 31 Dimensional drawing
13b Ratings
Boiler Manual
Table
Boiler ratings
Weil-McLain 500 Blaine Street Michigan City, IN
Handling ceramic fiber and fiberglass materials
GOLD CGs Gas-FiredWater Boiler — Boiler Manual