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Weil-McLain 550-110-260/02002 manual Contents, 6–11, Water piping, Gas piping, Start-up, Operation

Models: 550-110-260/02002

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Contents

GOLD CGs Gas-Fired Water Boiler

Contents
How it works	2–3
Hazard definitions	4
Please read before proceeding	5
1. Prepare boiler location	6–11
2. Prepare boiler	12–13
3. Water piping	14–23
4. Venting & combustion air	24
5. Gas piping	24–25
6. Field wiring	26
7. Start-up	27–29
8. Check-out procedure	30
9. Operation	31–34
10. Service and maintenance	35–40
11. Troubleshooting	41–51
12. Replacement parts	52–57
13. Dimensions and ratings	58–59

Hazard definitions

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.

Indicates presence of hazards that will cause severe personal injury, death or substantial property damage.

Indicates presence of hazards that can cause severe personal injury, death or substantial property damage.

Indicates presence of hazards that will or can cause minor personal injury or property damage.

Indicates special instructions on installation, operation or maintenance that are important but not related to personal injury or property damage.

4	Part number 550-110-260/0200

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Weil-McLain 550-110-260/02002 manual Contents, 6–11, Water piping, Gas piping, Start-up, Operation, Replacement parts

Contents

Page How it works GOLD CGs Gas-FiredWater BoilerPage Contents 12. Replacement parts6–11 3. Water pipingInstaller Please read before proceedingBoiler Manual User1a Prepare boiler location — codes & checklist Installations must follow these codesGOLD CGs Gas-FiredWater Boiler Before locating the boiler, check the followingResidential garage installation 1b Prepare boiler location — clearancesFlooring and foundation Provide the following clearances1c Prepare boiler location — vent system Removing from existing ventCGs special vent system GOLD CGs Gas-FiredWater Boiler1d Prepare boiler location — contamination Air contaminationBoiler Manual Table 1 Corrosive contaminants1e Prepare boiler location — air openings CGs combustion air optionsSizing air openings Special considerationsDirect exhaust vent installation Direct vent installationBoiler Manual Room Air Openings2a Prepare boiler — placement & setup Orifice replacement procedurePlace boiler/crate near position Inspect orifices and burners2b Prepare boiler — pressure test Perform hydrostatic pressure testBoiler Manual Prepare boiler for testPressure/temperature gauge 3a Water piping — general informationGeneral piping information Circulator3b Water piping — single-zonesystem Expansion tankBoiler Manual Closed-typeexpansion tank - Figure3c Water piping — multiple zones Zoning with zone valves, return temp over 130 FZoning with circulators, return temp over 130 F GOLD CGs Gas-FiredWater Boilertypical piping — multiple-zoneinstallations Boiler ManualZoning with circulators — return water 130 F or higherTemperature gauges Valve adjustment 3d Water piping — low temp systemsPrimary/secondary preferred bypass piping method GOLD CGs Gas-FiredWater Boilerprimary/secondary preferred bypass piping for radiant heating or converted gravity systemsBoiler Manual Figure3e Water piping - low temp systems Temperature gauges Valve adjustmentGOLD CGs Gas-FiredWater Boiler Boiler-bypasspiping methodboiler-bypassalternate piping — Boiler Manualfor radiant heating or converted gravity systems Figure 10 Boiler-bypasspipingValve adjustment 3f Water piping - low temp systemsGOLD CGs Gas-FiredWater Boiler System-bypasspiping method3f system-bypassalternate piping — 3g Water piping — refrigeration systemfor converted gravity or steam systems Prevent chilled water from entering boilerConnecting gas supply piping to boiler 4Venting and combustion air5Gas piping GOLD CGs Gas-FiredWater BoilerBoiler Manual 5 Gas piping continuedNatural Gas 6Field wiring Wiring connectionsElectrical installation must comply with GOLD CGs Gas-FiredWater Boiler7a Start-up— preparation Determine if water treatment is neededCheck for gas leaks Fill the system with water7a Start-up— preparation continued 7b Start-up- operate boilerInspect system water piping Final check before starting boiler7b Start-up— operate boiler continued 7c Start-up— if boiler doesn’t startCheck burner flames Check forInstallation and service certificate 8Check-outprocedure — checklistGOLD CGs Gas-FiredWater Boiler 9a Operation — sequence Boiler ManualFigure 19 Schematic wiring diagram 9b Operation — wiring diagramsGOLD CGs Gas-FiredWater Boiler Legend for ladder wiring diagram G PowerR Press switch Boiler ManualFOR YOUR SAFETY READ BEFORE OPERATING 9c Operation - lighting instructionsOPERATING INSTRUCTIONS TO TURN OFF GAS TO THE APPLIANCE10a Service and maintenance — schedule Service technicianOwner maintenance Table 5 Service and maintenance schedules10b Service & maintenance — annual start-up InspectReported problems GOLD CGs Gas-FiredWater BoilerService InspectBoiler Manual Burners, base and inlet air box10b Service & maint. — annual start-up continued Start-upCheck/test GOLD CGs Gas-FiredWater BoilerBoiler Manual Boiler relief valvelever must be operated AT LEAST Figure 23 Relief valve, typical10b Service & maint. - annual start-up Cleaning boiler heating surfacesReview with owner GOLD CGs Gas-FiredWater Boiler11a Troubleshooting — procedure Before troubleshootingCheck the following VERIFY PROPER OPERATION AFTER SERVICING11b Troubleshooting — air pressure switch Check pressure switch settingTroubleshooting air pressure reading Table 6 Pressure switch setpoint11c Troubleshooting — control module Control indicator lights — lockout modesControl indicator lights — non-lockoutmodes Troubleshooting the control module11c Troubleshooting — control module continued GOLD CGs Gas-FiredWater BoilerFigure 25 Control module connections 120 VAC IN11d Troubleshooting — control module lights CHART 1 — Troubleshooting POWER light statusIs 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 Boilercontinued CHART 3 — PRESS SWITCH & POWER lights flashingIs 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?continued Boiler ManualNatural gas — 5.0 w.c. min/14.0 w.c. max 11d Troubleshooting — control module lights Does the ohmmeter indicate the switch is closed?Is PRESS SWITCH light flashing? GOLD CGs Gas-FiredWater BoilerDoes voltmeter show 120 VAC across pins? Are limit switch contacts closed?Boiler Manual continued12a Replacement parts Section assemblyBase assembly Jacket assemblyPage Page Page Page Page Figure 31 Dimensional drawing 13a DimensionsGOLD CGs Gas-FiredWater Boiler 13b Ratings Boiler ManualTable Boiler ratingsGOLD CGs Gas-FiredWater Boiler — Boiler Manual Handling ceramic fiber and fiberglass materialsWeil-McLain 500 Blaine Street Michigan City, IN