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Weil-McLain
550-110-260/02002 manual
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
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Image 55
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Contents
Page
GOLD CGs Gas-FiredWater Boiler
How it works
Page
3. Water piping
Contents
12. Replacement parts
6–11
User
Installer
Please read before proceeding
Boiler Manual
Before locating the boiler, check the following
1a Prepare boiler location — codes & checklist
Installations must follow these codes
GOLD CGs Gas-FiredWater Boiler
Provide the following clearances
Residential garage installation
1b Prepare boiler location — clearances
Flooring and foundation
GOLD CGs Gas-FiredWater Boiler
1c Prepare boiler location — vent system
Removing from existing vent
CGs special vent system
Table 1 Corrosive contaminants
1d Prepare boiler location — contamination
Air contamination
Boiler Manual
Special considerations
1e Prepare boiler location — air openings
CGs combustion air options
Sizing air openings
Room Air Openings
Direct exhaust vent installation
Direct vent installation
Boiler Manual
Inspect orifices and burners
2a Prepare boiler — placement & setup
Orifice replacement procedure
Place boiler/crate near position
Prepare boiler for test
2b Prepare boiler — pressure test
Perform hydrostatic pressure test
Boiler Manual
Circulator
Pressure/temperature gauge
3a Water piping — general information
General piping information
Closed-typeexpansion tank - Figure
3b Water piping — single-zonesystem
Expansion tank
Boiler Manual
GOLD CGs Gas-FiredWater Boiler
3c Water piping — multiple zones
Zoning with zone valves, return temp over 130 F
Zoning with circulators, return temp over 130 F
— return water 130 F or higher
typical piping — multiple-zoneinstallations
Boiler Manual
Zoning with circulators
GOLD CGs Gas-FiredWater Boiler
Temperature gauges Valve adjustment
3d Water piping — low temp systems
Primary/secondary preferred bypass piping method
Figure
primary/secondary preferred bypass piping
for radiant heating or converted gravity systems
Boiler Manual
Boiler-bypasspiping method
3e Water piping - low temp systems
Temperature gauges Valve adjustment
GOLD CGs Gas-FiredWater Boiler
Figure 10 Boiler-bypasspiping
boiler-bypassalternate piping —
Boiler Manual
for radiant heating or converted gravity systems
System-bypasspiping method
Valve adjustment
3f Water piping - low temp systems
GOLD CGs Gas-FiredWater Boiler
Prevent chilled water from entering boiler
3f system-bypassalternate piping —
3g Water piping — refrigeration system
for converted gravity or steam systems
GOLD CGs Gas-FiredWater Boiler
Connecting gas supply piping to boiler
4Venting and combustion air
5Gas piping
Boiler Manual
5 Gas piping continued
Natural Gas
GOLD CGs Gas-FiredWater Boiler
6Field wiring
Wiring connections
Electrical installation must comply with
Fill the system with water
7a Start-up— preparation
Determine if water treatment is needed
Check for gas leaks
Final check before starting boiler
7a Start-up— preparation continued
7b Start-up- operate boiler
Inspect system water piping
Check for
7b Start-up— operate boiler continued
7c Start-up— if boiler doesn’t start
Check burner flames
Installation and service certificate
8Check-outprocedure — checklist
GOLD CGs Gas-FiredWater Boiler
Boiler Manual
9a Operation — sequence
Figure 19 Schematic wiring diagram
9b Operation — wiring diagrams
GOLD CGs Gas-FiredWater Boiler
Boiler Manual
Legend for ladder wiring diagram
G Power
R Press switch
TO TURN OFF GAS TO THE APPLIANCE
FOR YOUR SAFETY READ BEFORE OPERATING
9c Operation - lighting instructions
OPERATING INSTRUCTIONS
Table 5 Service and maintenance schedules
10a Service and maintenance — schedule
Service technician
Owner maintenance
GOLD CGs Gas-FiredWater Boiler
10b Service & maintenance — annual start-up
Inspect
Reported problems
Burners, base and inlet air box
Service
Inspect
Boiler Manual
GOLD CGs Gas-FiredWater Boiler
10b Service & maint. — annual start-up continued
Start-up
Check/test
Figure 23 Relief valve, typical
Boiler Manual
Boiler relief valve
lever must be operated AT LEAST
GOLD CGs Gas-FiredWater Boiler
10b Service & maint. - annual start-up
Cleaning boiler heating surfaces
Review with owner
VERIFY PROPER OPERATION AFTER SERVICING
11a Troubleshooting — procedure
Before troubleshooting
Check the following
Table 6 Pressure switch setpoint
11b Troubleshooting — air pressure switch
Check pressure switch setting
Troubleshooting air pressure reading
Troubleshooting the control module
11c Troubleshooting — control module
Control indicator lights — lockout modes
Control indicator lights — non-lockoutmodes
120 VAC IN
11c Troubleshooting — control module continued
GOLD CGs Gas-FiredWater Boiler
Figure 25 Control module connections
Is POWER light
11d Troubleshooting — control module lights
CHART 1 — Troubleshooting POWER light status
Is POWER light off?
GOLD CGs Gas-FiredWater Boiler
11d Troubleshooting — control module lights
CHART 2 — TSTAT CIRC & POWER lights flashing
Do the TSTAT and POWER lights still flash?
Does the ohmmeter indicate the switch is closed?
continued
CHART 3 — PRESS SWITCH & POWER lights flashing
Is PRESS SWITCH light flashing?
Are FLAME and POWER lights flashing?
11d Troubleshooting — control module lights
Do FLAME and POWER lights still flash?
Are FLAME & POWER lights flashing?
continued
Boiler Manual
Natural gas — 5.0 w.c. min/14.0 w.c. max
GOLD CGs Gas-FiredWater Boiler
11d Troubleshooting — control module lights
Does the ohmmeter indicate the switch is closed?
Is PRESS SWITCH light flashing?
continued
Does voltmeter show 120 VAC across pins?
Are limit switch contacts closed?
Boiler Manual
Jacket assembly
12a Replacement parts
Section assembly
Base assembly
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Figure 31 Dimensional drawing
13a Dimensions
GOLD CGs Gas-FiredWater Boiler
Boiler ratings
13b Ratings
Boiler Manual
Table
GOLD CGs Gas-FiredWater Boiler — Boiler Manual
Handling ceramic fiber and fiberglass materials
Weil-McLain 500 Blaine Street Michigan City, IN