Weil-McLain GOLD CGs User's Manual
Contents
1. l lt Z lt lt lt Check test e Gas piping Every 6 months e Cold fill and operating pressures e Air vents and air elimination Limit controls and cutoffs Expansion tank Boiler relief valve End of season Review e Review with owner Part No 550 1 10 261 0999 Owner maintenance see following pages for instructions Check boiler area Check air openings Check boiler pressure temperature gauge Check boiler interior piping Check venting system Check air vents Check boiler relief valve Check condensate drain system Check automatic air vents if used Test low water cutoff if used Clean vent termination air intake screens Oil inducer motor Operate relief valve Shut down procedure GOLD CGs User s Information Manual User maintenance procedures AJ Boiler must be serviced amp maintained NOTICE The boiler should be inspected and started annually at the beginning of the heating season only by a qualified service technician In addition the maintenance and care of the boiler designated on page 5 and explained on the following pages must be performed to assure maximum boiler effi ciency and reliability Failure to service and maintain the boiler and sys tem could result in equipment failure causing possible severe personal injury death or substantial property damage The following information provides detailed instructions for completi2. 550 110 261 0999 Read before proceeding Failure to adhere to the guidelines on this page can result in se vere personal injury death or substantial property damage Boiler service and maintenance To avoid electric shock disconnect electrical supply before per forming maintenance To avoid severe burns allow boiler to cool before performing main tenance You must maintain the boiler as outlined in the manual and have the boiler started up and serviced at least annually by a qualified service technician to ensure boiler system reliability Boiler operation Do not block flow of combustion or ventilation air to boiler This boiler is equipped with a control which will automatically shut down the boiler should air or vent be blocked If vent or air blockage Is easily accessible and removable remove it The boiler should attempt to restart within an hour If blockage is not obvious or cannot be re moved have the boiler and system checked by a qualified service tech nician Should overheating occur or gas supply fail to shut off do not turn off or disconnect electrical supply to pump Instead shut off the gas supply at alocation external to the appliance Do not use this boiler if any part has been under water mmedi ately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water Have the building monitored when i
3. below and call your service technician or gas supplier 12 Replace jacket front pane Pw SY P D 26070 White Rodgers 36C Gas valve Position indicator shown in ON position White Rodgers 36E Gas valve Honeywell VR8204 or VR8304 Gas valve Gas santol knob a TO TURN OFF GAS TO THE APPLIANCE _ Set the thermostat to lowest setting Turn off all electric power to the appliance if service is to be performed Remove jacket front panel Turn Gas control knob clockwise to OFF Do not force Ve we P Pe Replace jacket front panel Part No 550 110 261 0999 13 GOLD CGs User s Information Manual Common problems and solutions Common Causes Possible Corrections Rapid cycling boiler Thermostat installed where drafts Locate thermostat on inner wall away from turns on and off frequently F heat affect reading heat sources or cool drafts Heat anticipator in thermostat Adjust thermostat per manufacturer s adjusted incorrectly instructions Incorrect limit setting Set limit according to system needs Maximum setting is 220 F Increase limit setting to decrease cycling Insufficient water flow through Check all valves to and from boiler Return boiler to proper setting Confirm circulator size Frequent release of water Expansion tank sized too small Call qualified service technician to check through relief valve expansion tank operati
4. combustion air Remove any contaminating products See outlet or vent flueway supply See page 4 in this page 4 in this manual corrosion manual Provide outside air for combustion Kit available through Weil McLain distributor Have qualified service technician pipe up kit Condensation of combustion Have qualified service technician inspect gases in boiler sections system piping and controls to verify proper regulation of return water temperature Some radiators or Air in system Bleed air from system through air vents in baseboard units do not radiators or baseboard units heat or are noisy Low system pressure Fill to correct pressure Check for leaks in boiler or piping Have qualified service technician repair at once High limit set too low Adjust high limit to higher setting Part No 550 1 10 261 0999 15 16 Weil McLain Limited Warranty for Residential amp Commercial Cast Iron Boilers RESIDENTIAL WATER WARRANT Y Limited Lifetime RESIDENTIAL STEAM WARRANT Y Limited 10 Year COMMERCIAL WARRANTY Limited 10 Year NOTE The residential steam and water warranties do not cover residential boilers installed in buildings other than one or two family dwelling units unless they are buildings with individual boilers foreach dwelling unit First Year All Residential amp Commercial Cast Iron Boilers Limited Warranty for Cast Iron Boilers Weil McLain warrants that its cast iron b
5. death or substantial property damage Check venting system 1 Visually inspect the flue gas vent piping for any signs of blockage leakage or joints or deteriora tion of the piping Notify your qualified service technician at once if you find any problem Failure to inspect the vent system as noted above and havethem repaired by a qualifed service technician can result in vent system failure causing severe personal injury or death Figure 1 Relief valve ie Part No 550 110 261 0999 Check boiler relief valve 1 Inspect the boiler relief valve see Figure 1 and the relief valve discharge pipe for signs of weeping or leakage 2 Ifthe relief valve often weeps the expansion tank may not be working properly Immediately con tact your qualified service technician to inspect the boiler and system Check condensate drain system 1 Inspect condensate drain fittings and tubing Verify that condensate can flow freely to drain Check automatic air vents if used 1 SeeFigure 2 2 Remove the cap from any automatic air vent in thesystem and check operation by depressing valve B slightly with the tip of a screwdriver 3 If the air vent valve appears to be working freely and not leaking replace cap A twisting all the way on 4 Loosen cap A oneturn to allow vent to operate 5 Havevent replaced if it does not operate correctly Figure 2 Automatic air vent GOLD CGs User s Information Manu
6. gas control knob Never use tools If the knob will not turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e Do not touch any electric switch do not use any phone in your building If you cannot reach your gas supplier call the fire department M A o STOP Read the safety information above on this label Set the thermostat to lowest setting Turn off all electrical power to the appliance Remove jacket front panel Thisapplianceisequipped with an ignition devicewhich automatically lights the burner Do not try to light the burner by hand Turn Gas control knob clockwise to OFF 7 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above If you don t smell gas go to the next step 8 Turn Gas control knob counterclockwise w to ON 9 Turn on all electric power to the appliance 10 Set thermostat to desired setting 11 If the appliance will not operate follow the instructions TO TURN OFF GAS TO APPLIANCE
7. have caused unusual deposits in the cast iron sections These warranties extend only to the first retail purchaser of the boiler and only to a boiler that has not been moved from its original installation site THE WARRANTIES DESCRIBED ABOVE ARE IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY WEIL McLAIN EXPRESSLY DISCLAIMS AND EXCLUDES ANY LIABILITY FOR CONSEQUENTIAL INCIDENTAL INDIRECT OR PUNITIVE DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY For prompt product warranty claims notify the installer who in turn will notify the Weil McLain distributor from whom he purchased the boiler If this action does not result in warranty resolution contact Weil McLain Consumer Relations Department 500 Blaine Street Michigan City Indiana 46360 2388 with details in support of the warranty claim Alleged defective part or parts must be returned through trade channels in accordance with the Weil McLain procedure currently in force for handling returned goods for the purpose of inspection to determine cause of failure Weil McLain will furnish new part s to an authorized Weil McLain distributor who in turn will furnish the new part s to the heating contractor who installed the boiler If you have any questions about the coverage of this warranty contact Weil McLain at the address above WEIL McLAIN A United D
8. 2G Gas Fired Water Boller Users Information Manual If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier Part No 550 110 261 0999 Hazard definitions Boiler service and maintenance How to use this manual GOLD CGs User s Information Manual Please read this page first The following defined terms are used throughout this manual to bring attention to the pres ence of hazards of various risk levels or to important information concerning the life of the product CAUTION NOTICE Indicates presenceof hazardsthat 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 cau
9. AS TO APPLIANCE on the Lighting in structions on the inside of the jacket top panel You will also find these instructions on pages 12 and 13 of this manual Usethe Lighting instruction for the gas valve model installed on the boiler 2 Do not drain system unless exposure to freezing temperatures will Occur 3 Do not drain the system if it is filled with an antifreeze solution 4 Do not shut down boilers used for domestic water heating They must Operate year round Part No 550 1 10 261 0999 9 10 OO amp GOLD CGs User s Information Manual How the boiler works Control module The control module responds to signals from the room thermostat air pressure switch and boiler limit circuit to operate the boiler circulator pilot burner gas valve and inducer When room thermostat calls for heat the control module starts the system circulator and inducer The control module runs the inducer long enough to purge the boiler flue passages then opens the pilot valve and activates pilot ignition spark The control module allows up to 15 seconds to establish pilot flame If flame is not sensed within 15 seconds the control module will turn off the gas valve flash the Flame light and then enter a 15 second postpurge The control module will then start a new cycle This will continue indefinitely until pilot flame is established or power is interrupted Once pilot flame is proven the control module opens the
10. al User maintenance procedures Service periodically s 5 8 Clean vent termination amp air intake screens 1 Removeall lint and debris from both the boiler air intake screen and the flue discharge screen 2 The boiler control module will sense blockage of the air intake or flue and lockout if the blockage is excessive It will signal the failure by flashing the appropriate indicator lights on the control board 3 If removing the debris does not allow the boiler to operate correctly afterwards contact your qualifed service technician to inspect the boiler and vent air systems Test low water cutoff if installed 1 If the system is equipped with a low water cutoff test the low water cutoff periodically during the heating season following the low water cutoff manufacturer s instructions Service every 6 months Operate boiler relief valve 1 Before proceeding verify that the relief valve out let has been piped to asafe place of discharge avoid ing any possibility of scalding from hot water To avoid water damage or scalding due to valve operation a metal dis charge line must be connected to relief valve outlet and run to a safe place of disposal This dischargeline must be installed by a qualifed heating installer or service techni cian in accordance with the instruc tions in the Boiler manual The discharge line must be terminated so as to eliminate possibi
11. ar 20 15th year 25 16th year 30 17th year 35 18th year 40 19th year 45 20th year 50 21st year 55 22nd year 60 23rd year 65 24th year 70 25th year and beyond 75 All Residential amp Commercial Cast Iron Boilers These warranties are subject to the condition that the boiler must have been installed by a heating contractor whose principal occupation is the sale and installation of plumbing heating and or air conditioning equipment These warranties do not cover 1 Components that are part of the heating systems but were not furnished by Weil McLain as a part of the boiler 2 The workmanship of any installer of Weil McLain s boilers In addition this warranty does not assume any liability of any nature for unsatisfactory performance caused by improper installation 3 Any costs for labor for removal and reinstallation of the alleged defective part transportation to Weil McLain if necessary and any other materials necessary to perform the exchange 4 Improper burner adjustments control settings care or maintenance Information is included in the installation Instructions Owner s Information Manual and or Start up Service and Maintenance Instructions and other printed technical material furnished by Weil McLain with the boiler 5 Boilers operated with combustion air contaminated externally by chemical vapors or with improper fuel additives or with water conditions which may
12. ely or the boiler combustion air must be supplied from out side See WARNING above Check air openings 1 Verify that combustion and ventilation air open ings to the boiler room and or building are open and unobstructed 2 Verify that boiler vent discharge and air intake are clean and free of obstructions Remove any debris on the air intake or flue exhaust openings Check boiler pressure temperature gauge 1 Makesure the pressure reading on the boiler pres sure temperature gauge does not exceed 24 psig Higher pressure may indicate a problem with the expansion tank Contact a qualified service technician if problem persists Part No 550 110 261 0999 GOLD CGs User s Information Manual User maintenance procedures continued Check monthly Check boiler interior piping 1 Remove boiler jacket top 2 Visually inspect for leaks around internal piping circulators relief valve and other fittings mmedi ately call a qualified service technician to repair any leaks H ave leaks fixed at once by a qualifed service techni cian Continual fresh makeup water will reduce boiler life Minerals can build up in sections reducing heat transfer overheating cast iron and causing section fail ure Do not use petroleum based cleaning or sealing com pounds in boiler system Severe damage to boiler and system components can occur resulting in possible severe personal injury
13. gas valve to allow main burner flame When the room thermostat is satisfied the control module turns off the gas valve operates the inducer for a 15 second postpurge and waits for the next heat call The control module indicator lights show normal sequence when the lights are on steady When a problem occurs the control module flashes combinations of lights to indicate the most likely reason for the problem Transformer The control transformer reduces line voltage to 24 volts for the gas valve and limit circuit Inducer The inducer pulls flue gases through the boiler causing air to be pulled in through the air intake opening The inducer pushes the flue gases through the vent pipe as well Air pressure switch The air pressure switch signals the control module telling the control module whether air is moving through the inducer Water temperature limit switch The water temperature limit switch turns off the gas valve if the temperature in the boiler goes above its setting The circulator will continue to run as long as there is a call for heat Boiler circulator The boiler circulator circulates water through the external system piping NOTE The control module provides a pump exercising routine If the boiler is not operated for 30 days the control module will power the circulator for 30 seconds then off Other boiler components a supply to system f pressure temperaturegauge k pilot burner and bracket b return from syste
14. he boiler air from outside per the Boiler M anual If the boiler is installed in any area likely to cause contamination or if products which would contaminatetheair cannot beremoved you must pipe combustion air to the boiler air intake Contaminated combustion air will damage the boiler and vent system resulting in possible severe personal injury death or substantial property damage Do not operate a CGs boiler in a laundry room or pool facility for example without using ducted outside air These areas will always contain contaminants Products to avoid Areas likely to have contaminants N ew building construction Antistatic fabric softeners used in clothes dryers Chlorine type bleaches detergents and cleaning Garages with workshops solvents found in household laundry rooms Adhesives used to fasten building products and other similar products Part No 550 110 261 0999 GOLD CGs User s Information Manual Maintain boiler using schedule below Service technician covered in CGs Boiler Manual for use only by a qualified service technician Inspect e Reported problems e Boiler area Air openings Flue gas vent system and air piping Pilot and main burner flames Water piping Boiler heating surfaces Burners base and inlet air box Monthly Condensate drain system Service e Inducer motor e Oiled bearing circulators Start up Periodically e Perform start up per manual A 7 V
15. lity of se vere burns should the valve dis charge Read the boiler pressure temperature gauge to make sure the system is pressurized Lift the relief valve top lever slightly allowing wa ter to relieve through the valve and discharge pip Ing If water flows freely release the lever and allow the valve to seat Watch the end of the relief valve dis charge pipe to ensure that the valve does not weep after the line has had time to drain If the valve weeps lift the seat again to attempt to clean the valve seat If the valve continues to weep afterwards con tact your qualified service technician to inspect the valve and system If water does not flow from the valve when you lift thelever completely the valveor discharge line may be blocked Immediately shutdown the boiler fol lowing the instructions on the inside jacket top Lighting Instructions Call your qualified service technician to inspect the boiler and system Oil inducer motor 1 Useonly S A E 20 motor oil DO NOT use house hold universal oils Use only S A E 20 motor oil to lu bricate the inducer motor Do not use common universal household oils 2 Place a few drops of oil in each of the two oiler cups on the inducer motor Part No 550 110 261 0999 GOLD CGs User s Information Manual User maintenance procedures continued _I End of season shutdown Follow boiler shutdown procedure 1 Follow TO TURN OFF G
16. m g relief valve not visible I stainless steel burners c combustion air inlet hair vent connection m cast iron boiler sections d flueoutlet i flame rollout switch n flue collector e gas valve j air inlet box o junction box Part No 550 110 261 0999 CGs User s Information Manual CGs Gas Fired Induced Draft Water Boiler 11 Part No 550 1 10 261 0999 12 GOLD CGs User s Information Manual Lighting instructions Beforeattempting to start the boiler check the boiler pressure temperature gauge If boiler and system are full of water and properly pres surized the gauge should read at least 12 psig on most systems Operating the boiler without proper water content will damage boiler and controls and could result in severe personal injury death or substantial property damage Part No 550 110 261 0999 GOLD CGs User s Information Manual Lighting instructions FOR YOUR SAFETY READ BEFORE OPERATING sl A This appliance does not have a pilot It is equipped with an ignition device which auto matically lights the burner Do not try to light the burner by hand B Before OPERATING smell all around the ap D pliancearea for gas Besureto smell next to the floor because some gas is heavier than air and will settle on the floor See below iI WHAT TO DO IF YOU SMELL GAS e Do nottry to light any appliance C Use only your hand to turn the
17. ng the maintenance items listed in the maintenance schedule page 5 In ad dition to this maintenance the boiler must be serviced and started up at the beginning of each heating season by a qualified service technician I Check daily 0 2 2088 5 Check boiler area To prevent potential of severe personal injury death or substantial property damage eliminate all materials discussed below from the boiler vicinity If contami nants are found Remove products immediately from the area If they have been therefor an extended period call a qualified service technician to inspect the boiler and vent sys tem for possible damage from acid corrosion If products cannot be removed immediately call a qualified service technician to install an outside com bustion air source for the boiler if not already in stalled 1 Combustible flammable materials Do not store combustible materials gasoline or any other flam mable vapors or liquids near the boiler Remove immediately if found 2 Air contaminants Products containing chlorine or fluorine if allowed to contaminate the boiler intake air will cause acidic condensate in the vent and boiler This will cause significant damage to the vent and or boiler if allowed to continue Read the list of potential materials listed on page 4 of this manual If any of these products are in the room from which the boiler takes its combustion air they must be removed immediat
18. oilers are free from defects in material and workmanship for one year from the date of installation If any parts are found to be defective in manufacture Weil McLain will provide replacement of such defective parts Second Through Tenth Year Residential Water Steam Second Through Tenth Year Commercial Water Steam Limited Warranty for cast iron sections Weil McLain warrants that the cast iron sections of its water and steam boilers are free from defects in material and workmanship from the date of installation for the second through the tenth year If during such time period any section is found to be defective Weil McLain will provide replacement for the original cast iron section s Eleventh Year and Beyond Residential Water Only Limited Warranty for Cast Iron Sections Weil McLain warrants that the cast iron sections of its residential water boilers are free from defects in material and workmanship for the eleventh year and beyond from the date of installation If during such time period any section s is found to be defective Weil McLain will provide replacement for the original cast iron section s upon the payment of a proportionate charge based on the time the boiler has been in service The proportionate charge will be equal to the appropriate percentage of the list price of such section s at the time the warranty claim is made and will be determined as follows 11th year 5 12th year 10 13th year 15 14th ye
19. ominion Company al Weil McLain 500 Blaine Street Michigan City IN 46360 2388 http www weil mclain com Part No 550 110 261 0999
20. on and size Flooded expansion tank Call qualified service technician to check expansion tank operation Inoperative limit control Call qualified service technician to replace limit control Need to frequently add Leaks in boiler or piping Have qualified service technician repair makeup water leaks at once to avoid constant use of makeup water Makeup water can cause mineral deposits which in turn can cause boiler section failure Do not use petroleum base stop leak compounds Black water condition Oxygen corrosion due to leaks in Have qualified service technician repair at boiler and piping once Keep pH of water between 7 0 to 8 5 14 Part No 550 110 261 0999 GOLD CGs User s Information Manual Common problems and solutions Symptom Possible Corrections Popping or percolating Mineral deposits in sections due to Call qualified service technician to de lime noise heard in boiler constant use of makeup water boiler if necessary In some cases deposits will be too heavy to remove with de liming procedures Have qualified service technician repair leaks to eliminate need for constant makeup water Incorrect pH of boiler water Call qualified service technician to check pH level and correct pH should be maintained between 7 0 to 8 5 Insufficient water flow through Check all valves to and from boiler Return boiler to proper setting Confirm circulator size Metal flakes found in vent Contaminated
21. se 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 The User s Information Manual provides information to the boiler owner user for routine Operation and maintenance and emergency shutdown Detailed information on boiler instal lation operation start up service and parts isincluded in the C Gs Boiler Manual TheCGs Boiler Manual is intended only for use by a qualified service technician 1Oiee Learn precautions Prevent air contamination Maintain boiler Locate boiler components Start or Shutdown boiler Troubleshoot common problems Read use Pages Laundry room or pool make sure boiler air is piped to boiler per manual Read list of air contaminants you must avoid Have boiler air piped in if you can t avoid Set up a plan for maintaining the boiler using the schedule included in this manual Schedule an annual start up by a qualified ser vice technician before every heating season How the boiler works and illustration Use the Lighting instruction sheet for the gas valve installed on your boiler Ask your service technician if you are unsure which one Use the common problems solutions table to resolve typical heating system boiler problems Part No 550 110 261 0999 GOLD CGs User s Information Manual STOP Part No
22. t is vacant for an extended period Safety controls can shut down the boiler at any time The loss of heat can result in significant damage due to freezing Boiler water DO NOT use petroleum based cleaning or sealing compounds in boiler system Water seal deterioration will occur causing leakage be tween sections and damage to heating system components This can result in substantial property damage DO NOT use homemade cures or boiler patent medicines Serious damage to boiler personnel and or property may result Continual fresh makeup water will reduce boiler life M ineral build up in sections reduces heat transfer overheats cast iron and causes section failure Addition of oxygen and other gases can cause internal corrosion Leaks in boiler or piping must be repaired at once to pre vent makeup water Do not add cold water to hot boiler Thermal shock can cause sec tions to crack GOLD CGs User s Information Manual Prevent combustion air contamination Air contamination Common household and hobby products often con ageand presenting a possible threat of flue gas spillage tain fluorine or chlorine compounds When these into the building chemicals passthrough the boiler they can form strong Please read the information below If the contaminat acids in the vent system or boiler The acid can eat ing chemicals will be present have your installer pipe through the vent or boiler wall causing serious dam t
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