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Weil-McLain 550-110-260/02002 Boiler User Manual

1. or Vertical Duct l Sa NZ CGs D Air from Outside or Attic Lower Opening in Floor Duct Outside 12 Max e Tore Ventilated crawl space 26007 each opening 1 square inch free area per 4 000 Btuh input of other appliances plus CGs each opening 1 square inch free area per 4 000 Btuh input of CGs each opening 1 square inch free area per 4 000 Btuh input of other appliances only not CGs 3 S 1 square inch 1 square inch 1 square inch E free area per free area per free area per Clearance around KR E 1 000 Btuh input of 4 000 Btuh input 1 000 Btuh input of Poller is NO LESS d EI ee other appliances of CGs other appliances Figure 1 page 7 E plus CGs only not CGs of this manual 7 2 Openings 2 Openings 2 Openings NO Openings are B Air Directly Ba each opening each opening each opening needed provided from Outside T Z opening S 1 square inch 1 square inch 1 square inch E free area per free area per free area per Clearance around AH 4 000 Btuh input of 4 000 Btuh input 4 000 Btuh input of oe ela s es other appliances of CGs other appliances Figure 1 page 7 plus CGs only not CGs of this manual WA 2 Openings 2 Openings 2 Openings NO Openings are GE wd a each opening each opening each opening needed provided ir from Outside ax
2. Boiler Manual Inspect Eliminate all system or boiler leaks Continual fresh makeup water will reduce boiler life Minerals can build up in sections reducing heat transfer overheating cast iron and causing section failure Leaking water may also cause severe property damage Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to boiler will occur resulting in substantial property damage Electrical shock hazard Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this instruction manual Failure to turn off electrical power could result in electrical shock causing severe personal injury or death Boiler heating surfaces 1 Disconnect the vent pipe at the boiler inducer outlet connection after turning off power to the boiler 2 Use a bright light to inspect the flue pipe interior and inducer interior 3 Inspect the boiler vent outlet area and heating surfaces by looking through the opening 4 Ifthe vent pipe or inducer interior show evidence of soot follow Cleaning boiler heating surfaces in this manual section to remove the flue collector and clean the boiler if necessary after close inspection of boiler heating surfaces If there is evidence of rusty scale deposits check the water piping and control system to make sure the boiler return water temperature is properly maintained per this manual 5
3. E 120 VAC IN sl e Il Sek 24 VAC 24 VAC from transformer Ground O A Green 5 lt h20 vac N EE ZT White 120 VAC to inducer motor High voltage to spark electrode 120 VAC to transformer 120 VAC IN 24 VAC control circuits 24 VAC from transformer 120 VAC to inducer motor 120 VAC to circulator Sense wire to flame sensor 120 VAC to circulator Flame sense wire to pilot Part number 550 110 260 0200 Boiler Manual 1 ld Troubleshooting control module lights Usually indicates reversed 120 VAC polarity if POWER light flashes by itself WARNING Electrical shock hazard Wherever you see ATURN OFF POWER follow the instructions Failure to follow instructions could result in severe personal injury death or substantial property damage Is POWER light off No Yes Is POWER light Flashing Flashing with On steady alone another light not flashing e Make sure service switch or circuit breaker is on or fuses are good e Remove 120 VAC IN plug Figure 25 item 3 page 44 on control module e Using voltmeter check across top and bottom pins of 120 VAC IN plug Does voltmeter indicate 120 VAC No Yes Problem is with incoming electricity Have licensed electrician repair circuit
4. HIGH piLoT VOLTAGE FLAME T SENSOR Control module low voltage section 71033 33 9c Figure 21 GOLD CGs Gas Fired Water Boiler Lighting instructions Operation lighting instructions ER FOR YOUR SAFETY READ BEFORE OPERATING QQ A Before OPERATING smell all around the This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor See below WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance i If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life C Use only your hand to turn the 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 Do not touch any electric switch do not use any phone in your building
5. 2 If relief valve has tended to weep frequently the expansion tank may be waterlogged or undersized Closed type tank tank is most likely waterlogged Install a tank fitting if not already installed Then check fill level per fitting manufacturer s instructions If fill level is correct check tank size against manufacturer s instructions Replace with a larger tank if necessary Diaphragm or bladder type first check tank size to be sure it is large enough for the system If size is too small add additional tank s as necessary to provide sufficient expansion If tank size is large enough remove tank from system and check charge pressure usually 12 psig for residential applications If tank wont hold pressure membrane has been damaged Replace tank Boiler relief valve 1 Inspect the relief valve and lift the lever to verify flow as in the following warnings excerpted from a relief valve manufacturer s warning label Before operating any relief valve ensure that it is piped with its discharge in a safe area to avoid severe scald potential Read manual section 3a before proceeding further Safety relief valves should be reinspected AT LEAST ONCE EVERY THREE YEARS by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and Part number 550 110 260 0200 discharge line have not
6. Gas piping 1 Sniff near floor and around boiler area for any indication of a gas leak 2 Test gas piping using bubble test per section 5 of this manual if there is any indication of a leak Cold fill and operating pressures 1 While the system is cold note the pressure reading on the boiler pressure temperature gauge Verify that cold fill pressure is correct 2 Watch the pressure as the boiler and system heat up to ensure pressure rise is normal Too high a rise would indicate a waterlogged or undersized expansion tank Air vents and air elimination 1 Inspect automatic air vents if used Also inspect air separators to ensure they are operational 2 The cap must be unscrewed one turn to allow air to escape 3 See Figure 22 If the air vent is leaking remove cap A and briefly push valve B and then release to clean the valve seat 4 Replace cap A by twisting all the way onto valve B and then unscrewing one turn Limit controls and cutoffs 1 Inspect and test the boiler limit control Verify operation by turning control set point below boiler temperature Boiler should cycle off Return dial to original setting 2 Inspect and test additional limit controls or low water cutoffs installed on system Figure 22 Automatic air vent typical 26031 eal Expansion tank 1 Expansion tanks provide space for water to move in an out as the heating system water expands due to temperature increase or co
7. Hydrochloric acid muriatic acid Furniture refinishing areas and establishments Cements and glues New building construction Antistatic fabric softeners used in clothes dryers Remodeling areas Chlorine type bleaches detergents and cleaning solvents found in household laundry rooms Garages with workshops Adhesives used to fasten building products and other similar products Part number 550 110 260 0200 10 le GOLD CGs Gas Fired Water Boiler Prepare boiler location air openings CGs combustion air options Using inside air direct exhaust vent The CGs boiler can use inside air if no contaminants are present in the boiler space If contaminants are likely to be present install the CGs boiler as a direct vent appliance using the appropriate vent supplement and the instructions in this manual Using outside air direct vent Combustion air can be ducted directly from outside to the CGs boiler air intake fitting This method is defined as direct vent also referred to as sealed combustion Refer to the appropriate vent supplement and the instructions in this manual Two options are available sidewall or vertical direct vent Each requires a special vent component kit Sizing air openings Air openings provide for ventilation as well as combustion air to prevent overheating of the boiler controls and boiler space Air is also needed for other appliances located in the
8. TSTAT CIRC light flashing alah PRESS SES Chart 3 Chart 5 light flashing FLAME light flashing aan SIE For insufficient heat or no heat problem go to Chart 7 if POWER light is on steady with no other light flashing e Reconnect 120 VAC IN plug e Remove 120 VAC transformer PRIMARY plug Figure 25 item 2 page 44 on control module e Using voltmeter check across top and bottom pins of PRIMARY receptacle Does voltmeter indicate 120 VAC No Yes e Usually indicates polarity on incoming 120 VAC power line is wrong e ATURN OFF POWER A at service switch or breaker then reverse the HOT and NEUTRAL wires entering the boiler in the J box e Restore POWER at service switch or breaker Is POWER light flashing now Replace control module Retest No Yes e Reinstall 120 VAC transformer PRIMARY plug e Remove 24 VAC transformer plug Figure 25 item 5 page 44 on control module e Using voltmeter check across pins of receptacle Does voltmeter indicate 24 VAC No Yes Have system checked by a licensed electrician If problem persists call your Boiler should now operate normally local Weil McLain sales representative Part number 550 110 260 0200 Replace transformer Retest Replace control module Retest 45 1 GOLD CGs Gas Fired Water Boiler ld Troubleshooting
9. shank self closing valve Fittings shown are shipped loose with boiler 3 Drain valve 29 Conbraco 31 606 01 511 210 423 Fittings shown are included with boiler Hammond 710 511 246 392 Valve Matco Norca 205F04 511 246 392 Watts BD 2C 511 246 392 4 Circulator Bell amp Gossett NRF 22 103253 511 405 118 Fittings shown are shipped loose with boiler Grundfos UP15 42FR TB4 511 405 126 Taco 007 511 405 113 5 Circulator gasket universal 2 per boiler Weil McLain 590 317 535 not Circulator hardware kit includes Weil McLain shown 1 flange 2 nuts 2 screws 1 gasket 1 NPT CGs 3 through CGs 5 381 300 494 1 NPT CGs 6 381 300 495 6 Circulator wiring harness kit with Molex loose 381 354 528 56 Part number 550 110 260 0200 Boiler Manual 12f Replacement parts controls Figure 30 Gas control assembly Item Description Manufacturer Manufacturer s Weil McLain number part number part number Natural gas components 1 Gas valve 2 x 2 CGs 3 through CGs 6 Honeywell VR8204A2001 381 356 532 _ 2 Pilot assembly kit with orifice and aluminum pilot Weil McLain 511 330 080 gas tubing EH M Propane gas components 1 Gas valve 2 x 1 2 CGs 3 through CGs 6 Honeywell VR8204M2701 381 356 533 2 Pilot assembly kit with orifice and aluminum pilot Weil McLain 511 330 081 B gas tubing ge j Se L Natural gas and propane gas components 3 Control module
10. Through horizontal p m Duct g ducts me al 1 square inch 1 square inch 1 square inch 2 g free area per free area per free area per Clearance around E fo D D H S 2 000 Btuh input of 4 000 Btuh input 2 000 Btuh input of Poller is NO LESS GM crea S other appliances of CGs other appliances Figure 1 page 7 Mex 7 plus CGs only not CGs of this manual Outside or ventilated attic 2 Openings 2 Openings 2 Openings NO Openings are needed provided Clearance around boiler is NO LESS than shown in Figure 1 page 7 of this manual Exception to combustion air opening rules NO combustion air openings are needed when the boiler and other appliances are installed in a space with a volume NO LESS than 50 cubic feet per 1 000 Btuh of all installed appliances Sum the total input of all appliances in MBH 1 000 s of Btuh and multiply this number times 50 Building must not be of Tight construction see page 10 Example For total input of 100 MBH 100 000 Btuh minimum volume is 50 x 100 5 000 cubic feet At a ceiling height of 8 feet space must have at least 5 000 8 625 square feet 25 feet x 25 feet for instance Part number 550 110 260 0200 11 2a GOLD CGs Gas Fired Water Boiler Prepare boiler placement amp setup Place boiler crate near position 1 Leave boiler in crate and on pallet until installation site is ready 2 Move entire crate and pallet next to selected l
11. United 1107 1 511 330 087 Technologies not shown Wiring harness control gt _Weil McLain 591 391 894 not shown Wiring harness 120V Weil McLain 591 391 900 4 Air pressure switch Tri Delta 1 79 I W C CGs 3 PPS10171 3013 511 624 401 1 48 I W C CGs 4 PPS10171 3014 511 624 402 1 22 I W C CGs 5 PPS10171 3015 511 624 403 0 95 I W C CGs 6 as GES tad PPS10171 3016 511 624 404 5 Control transformer 511 842 370 notshown Tubing air pressure switch 0 12 I D silicone Lydall red to collector hood 590 317 650 white to transition 590 317 651 Part number 550 110 260 0200 57 GOLD CGs Gas Fired Water Boiler l3a Dimensions Figure 31 Dimensional drawing Supply piping note 7 2 Return piping note 1 Relief valve 34 NPT v2 NPT to expansion tank air vent 3 Diameter vent ALL DIMENSIONS IN INCHES 3 3 2 Dia air pipe connection Gas supply piping Drain valve 9 Gas supply entrance right or left side 0 Pressure temperature gauge Note1 Boiler supply and return tappings are both 114 NPT See Table 3 page 14 for recommended system sup ply and return piping sizes Boiler circulator is shipped loose Circulator may be mounted on either boiler supply or return piping Circulator flange provided with boiler is same size as recommended pipe size in Tabl
12. You may use any of the vent systems covered by the CGs Venting Supplements included in the envelope assembly The CGs vent starter is a special item designed only for the CGs boiler available from each vendor Do not attempt to connect the vent to the CGs boiler with any other means DO NOT mix components from different systems The vent system could fail causing leakage of flue products into the living space Vent termination and combustion air supply The CGs boiler may be vented through the roof or through a side wall Follow the appropriate vent supplement for the vent system chosen The maximum vent length depends on boiler size Refer to the vent supplement to determine acceptable vent length Combustion air for the CGs boiler may be from inside or ducted directly to the boiler from outside For outside air direct vent installation two options are available for the flue air termination The air supply must ALWAYS terminate at the same location as the flue using either 1 Vertical direct vent installation Obtain the Weil McLain Through Roof or Through Unused Chimney termination kit and supplement Refer to Vertical Direct Venting Venting Supplement packed with the kit and to the vent manufacturer s instructions for the vent material chosen 2 Sidewall direct vent installation Use the Vent Air Intake termination kit shipped with the boiler Refer to CGs Direct Venting Sidewall amp Direct Exhaust
13. Irrigate immediately E Breathing Fresh air REMOVAL OF FIBERGLASS WOOL OR INSTALLATION OF FIBERGLASS WOOL COMBUSTION CHAMBER LINING OR BASE PANELS This product contains fiberglass jacket insulation and ceramic fiber materials in combustion chamber lining or base panels in gas fired products Airborne fibers from these materials have been listed by the State of California as a possible cause of cancer through inhalation E Avoid breathing dust and contact with skin and eyes Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for fiberglass wool at the time this document was written Other types of respirators may be needed depending on the job site conditions Current NIOSH recommendations can be found on the NIOSH web site at http www cdc gow niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this web site Wear long sleeved loose fitting clothing gloves and eye protection E Operations such as sawing blowing tear out and spraying may generate airborne fiber concentration requiring additional protection E Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid E Eye Irrigate immediately E Breathing Fresh air Weil McLain Un WEIL McLAIN 500 Blaine Street A United Dominion Company Michigan City IN 46360 2388 http www weil
14. 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 CAUTION NOTICE 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 Part number 550 110 260 0200 Boiler Manual Please Installer Read all instructions before installing Follow all instructions in proper order to prevent personal injury or death e Also refer to CGs Venting Supplements e Consider piping and installation when determining boiler location Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee NOTICE read before proceeding User e This manual is for use only by your qualified heating installer service technician e Please refer to the User s Information Manual for your reference We recommend regular service by a qualified service technician at least annually When calling or wri
15. a low enough flow rate and high enough average temperature to prevent condensation even with low system return water temperature 3 Valve 7a regulates the system flow rate while valve 7b regulates the boiler flow rate 4 The boiler mounted temperature pressure gauge may be used in place of a separate gauge 8 Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners resulting in severe personal injury death or substantial property damage Radiant heating system piping should include a means of regulating the boiler return water temperature and the system supply temperature such as provided by an injection pumping control Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the system supply temperature is relatively constant DO NOT apply the methods of this manual if the system is equipped with an outdoor reset control Instead provide controls and piping which can regulate the boiler return water temperature at no less than 130 F regardless of system supply temperature Contact your Weil McLain representative for suggested piping and control methods Failure to prevent cold return water temperature to the boiler could cause corrosion damage to the sections or burners resulting in possible severe personal injury death or substantial property damage Part number 550 110 260 0200 Boiler Manual boiler b
16. where a Walls and ceilings exposed to the outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed and b Weather stripping has been added on openable windows and doors and c Caulking or sealants are applied to areas such as joints around windows and door frames between sole plates and floors between wall ceiling joints between wall panels at penetrations for plumbing electrical and gas lines and in other openings For buildings with such construction provide air openings into the building from outside sized per the appropriate case in Figure 3 if appliances are to use inside air for combustion and ventilation Exhaust fans and air movers The appliance space must never be under a negative pressure unless all appliances are installed as direct vent Always provide air openings sized not only to the dimensions required for the firing rate of all appliances but also to handle the air movement rate of the exhaust fans or air movers using air from the building or space Motorized air dampers If the air openings are fitted with motorized dampers electrically interlock the damper to Prevent the boiler from firing if the damper is not fully open Shut the boiler down should the damper close during boiler operation To accomplish this interlock wire an isolated contact proving the damper open in series with the thermostat input to the boiler The boile
17. 24 VAC between both air pressure switch terminals and ground 6 If manometer reading is above the setpoint of the switch see Table 6 but there is not 24 VAC between both air pressure switch terminals and ground replace air pressure switch Figure 24 Manometer connections fo N Va Suction Inclined tube manometer Pressure 26035 Table 6 Pressure switch setpoint for elevations above 2 000 ft contact your local Weil McLain sales office for details Boiler model number Inches W C CGs 3 1 79 CGs 4 1 48 CGs 5 1 22 CGs 6 0 95 Troubleshooting air pressure reading 1 If manometer reading is lower than the setpoint of the switch see Table 6 check for possible causes e blockage in hoses e obstruction in inducer housing outlet e loose inducer wheel on motor shaft e inducer motor not in proper rpm e inducer back plate not sealed properly e blockage in block assembly e blockage in flue pipe or termination e incorrect pressure switch Return to normal operation When pressure reading is correct and air pressure switch is operating properly remove tees and reinstall hoses to air pressure switch The boiler will not operate correctly unless pressure switch hoses are correctly located The red hose NOTICE connects from the right side negative hose barb to the flue collector The white hose connects from the left side positive hose barb of the switch to
18. 7 84 0 3 CGs 6 140 000 167 000 140 300 150 300 126 300 122 000 3 3 83 4 3 Notes 1 Add PIN for natural gas boiler PIL for propane gas made for unusual piping and pickup loads boiler CGs boilers require special venting consistent with Based on standard test procedures prescribed by the Category III or IV boiler Use only the vent materials and United States Department of Energy methods specified in CGs vent supplements CGs boilers Net I B R ratings are based on net installed radiation of may be direct vented using 3 diameter air piping as sufficient quantity for the requirements of the building specified in the direct vent supplements and nothing need be added for normal piping and As an Energy Star Partner Weil McLain has determined pickup Ratings are based on a piping and pickup that the CGs 3 meets the Energy Star guidelines for energy allowance of 1 15 An additional allowance should be efficiency NOTICE CGs boilers for residential radiant panel systems converted gravity heating systems or other low water temperature applications should be installed with balancing valves and bypass piping equal to the supply and return size to avoid excessive flue gas condensation due to lower operating water temperatures For alternate piping contact your Weil McLain sales office CSA design certified for installation on combustible flooring Tested for 50 psi working pressure Part number 550 110 260 0200 59 GOLD CGs Ga
19. NPT pipe plug Remove 11 4 nipple reducing tee and drain valve from accessory bag Install in boiler return connection as shown on page 3 and Figure 29 page 56 Install circulator on either the return or supply Remove 14 nipple 144 tee bushing and pressure temperature gauge from accessory bag Pipe to boiler supply connection as shown on page 3 and Figure 29 page 56 Use pipe dope sparingly Connect a hose to boiler drain valve the other end connected to a fresh water supply Make sure hose can also be used to drain boiler after test Connect a nipple and shutoff valve to system supply connection on the 144 tee This valve will be used to bleed air during the fill Valve and nipple are not included with boiler Connect a nipple and shutoff valve to system return connection at circulator flange if circulator installed on return This valve will be used to bleed air during the fill Valve and nipple are not included with boiler Fill and pressure test et dee Sr SS Open the shutoff valves you installed on supply and return connections Slowly open boiler drain valve and fresh water supply to fill boiler with water When water flows from shutoff valves close boiler drain valve Close shutoff valves Slowly reopen boiler drain valve until test pressure on the pressure temperature gauge reaches no more than 45 psig for boilers with 30 psig relief valve 75 psig for boilers with 50 psig relief valve Test for no
20. Reconnect vent to inducer outlet and replace all boiler components before returning to service Service mp u u E wm E E E em Inducer motor 1 With boiler power OFF place a few drops of S A E 20 motor oil in each of the two oil cups Use only S A E 20 motor oil to lubricate the inducer motor Do not use universal household oils Motor could be damaged resulting in possible severe property damage Part number 550 110 260 0200 6 Check inside and around boiler for evidence of any leaks from the boiler If found locate source of leaks and repair Burners base and inlet air box 1 After turning off power to the boiler remove the inlet air box top panel Figure 27 item 13 page 54 Inspect gasket item 14 Replace if necessary Inspect burners and all other components in the inlet air box and boiler base 4 If burners must be cleaned first remove item 4 Figure 27 page 54 Access the burner assembly by first removing burner baffle item 4 Then remove the screws securing the burner tray to the manifold Slide the burner tray out Then brush and vacuum the burners thoroughly making sure all ports are free of debris 5 Inspect the slotted jacket cooling openings in the bottom left and rear of the base pan Figure 27 item 1 page 54 6 Inspect the base insulation Pay attention to the WARNING on page 36 regarding working with insulation materials Verify that the insulation is intact and sec
21. available however adjust the valves such that the boiler mounted temperature pressure gauge reads at least 150 F when the system return water is cold approximately 60 F water temperature 1 Set the valves while the system is cool setting for the coldest expected water temperature usually 60 F since the system will often drop to room temperature between cycles 2 Start with valve 7a fully closed and 7b fully open Gradually open valve 7a while closing valve 7b until the temperature at gauge 8 reads 130 F when gauge 4a reads 60 F 4 Note that valve 7a regulates the amount of hot water from the boiler supply which mixes with return water Valve 7b regulates the amount of system water flowing through the boiler secondary loop Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners resulting in severe personal injury death or substantial property damage Radiant heating system piping should include a means of regulating the boiler return water temperature and the system supply temperature such as provided by an injection pumping control Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the system supply temperature is relatively constant DO NOT apply the methods of this manual if the system is equipped with an outdoor reset control Instead provide controls and piping which can regulate the boiler ret
22. been altered or tampered with illegally Certain naturally occurring conditions may corrode the valve or its components over time rendering the valve inoperative Such conditions are not detectable unless the valve and its components are physically removed and inspected This inspection must only be conducted by a plumbing contractor or authorized inspection agency not by the owner Failure to reinspect the boiler relief valve as directed could result in unsafe pressure buildup which can result in severe personal injury death or substantial property damage Following installation the valve lever must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear Certain naturally occurring mineral deposits may adhere to the valve rendering it inoperative When manually operating the lever water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage Before operating lever check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal otherwise severe personal injury may result If no water flows valve is inoperative Shut down boiler until a new relief valve has been installed 2 After following the above warning directions if the relief valve weeps or will not seat properly replace the relief valve Ensure that the reason for relief valve weeping is the valve and not over pressurization
23. boiler and check continuity across the two wires y If circuit isn t closed check external thermostat zone e Remove CIRCULATOR harness plug from valve relay etc wiring Correct problems and retry CIRCULATOR plug receptacle Figure 25 Item e Reconnect external thermostat wiring at boiler 7 page 44 Check with voltmeter across pins of Is thermostat circuit closed continuity across wires EE Does voltmeter show 120 VAC across pins No Yes No Yes w e Boiler is in standby i jl Are all red lights off Set thermostat to call for Replace control e Repair replace No Yes L p ro module circulator Retest D e Veri g e Retest e Repair replace erify Sequence of SS F wiring Retest Wait 30 seconds operation Figure 18 Are all red lights off page 31 4 No Yes A e Wait 5 minutes d Is FLAME light on Replace control Yes No module Retest Is LIMIT light on Vv e f you have sufficient heat boiler should be in normal operating sequence See normal sequence of operation Figure 18 No Yes e f you have less than sufficient heat D Ge Is vent or combustion air piping free of blockage e Check limit switch l Replace control module No Yes contacts with continuity e Retest e 4 checker e Correct conditions and Contact your Weil McLain Are limit switch contacts recheck operation sa
24. control module lights CHART 2 TSTAT CIRC amp POWER lights flashing Usually indicates 48 VAC on thermostat circuit stray voltage WARNING Electrical shock hazard Wherever you see ATURN OFF POWER follow the instructions Failure to follow instructions could result in severe personal injury death or substantial property damage Disconnect the two external wires connected to the boiler thermostat leads two black low voltage leads in J box Connect a voltmeter across these two incoming wires Close each thermostat zone valve and relay in the external circuit one at a time and check the voltmeter reading across the wires There should NEVER be a voltage reading If a voltage does occur under any condition check and correct the external wiring This is a common problem when using 3 wire zone valves Once the external thermostat circuit wiring is checked and corrected if necessary reconnect the external thermostat circuit wires to the boiler thermostat wires and allow the boiler to cycle Did you find a voltage across the two external thermostat circuit wires Yes Leave external boiler thermostat connection wires disconnected from boiler Troubleshoot the external thermostat circuit until you find the source of the stray voltage Pay close attention to the wiring connections to 3 wire zone valves Correct the problem and repeat the voltmeter test above verifying ther
25. i ke S Check Boiler valve System return gt gt pO Balancing 26019 valve ot Part number 550 110 260 0200 Figure 12 System bypass piping Zoning with zone valve or circulators return water 130 F or higher Alternative to boiler bypass piping Figures 10 and 11 3 System or zone circulator 7 System temperature valves see instructions to the left for adjusting valves 8 Blend temperature gauge 9 Relief valve 10 Automatic air vent with diaphragm type expansion tank or connect to tank fitting closed type expansion tank DO NOT use an automatic air vent when using closed type expansion tank It would allow air to leave the system causing waterlogging of the expansion tank 11 Fill valve 12 Diaphragm type or bladder type expansion tank if used For closed type expansion tank pipe from top of air separator to tank fitting as in Figure 5 Water piping refrigeration system Prevent chilled water from entering boiler Install boiler so that chilled medium is piped in parallel with the heating boiler Use appropriate valves to prevent chilled medium from entering boiler See Figure 13 for typical installation of balancing valve and check valve If boiler is connected to heating coils located in air handling units where they can be exposed to refrigerated air use flow control valves or other automatic means to prevent gravity circulation during cooling c
26. injury death or substantial property damage Figure 4 Diaphragm or bladder type expansion tank Piping to single zone system using Bee dg or bladder type expansion tank See Table 3 for piping sizes Cold From water system fill y To DIAPHRAGM G expansion tank and fittings Isolation T Isolation valve Pe ae Salve Relief To system valve Circulator Automatic air vent Circulator Alternate 26010 location Part number 550 110 260 0200 Figure 5 Closed type expansion tank Piping to single zone system umg closed type expansion tank See Table 3 for piping sizes CLOSED type expansion tank From ANN system 1 Cold water fill Isolation valve Isolation y valve NY To system Relief valve Circulator Circulator Alternate 26011 location 15 GOLD CGs Gas Fired Water Boiler C Piping multiple zones 16 Zoning with circulators return temp over 130 F Zoning with zone valves return temp over 130 F Piping for radiant heating systems or converted gravity systems Water piping multiple zones Follow instructions on pages 14 and 15 to install near boiler or single zone piping Also refer to Piping for radiant heating systems or converted gravity systems below if applicable See Figure 6 or Figure 7 to complete installation Size each circulator to individual circuit requirements Do not install circulat
27. mclain com 60 Part Number 550 110 260 0200
28. more than 10 minutes at 45 psig for boilers with 30 psig relief valve 75 psig for boilers with 50 psig relief valve Do not leave boiler unattended A cold water fill could expand and cause excessive pressure resulting in severe personal injury death or substantial property damage Make sure constant gauge pressure has been maintained throughout test Check for leaks Repair if found Leaks must be repaired at once Failure to do so can damage boiler resulting in substantial property damage DANGER Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to boiler will occur resulting in substantial property damage Drain and remove fittings l 2 3 Disconnect fill water hose from water source Drain boiler at drain valve or out hose whichever provides best access to drain Remove hose after draining if used to drain boiler Remove nipples and valves unless they will remain for use in the system piping Remove plug from relief valve tapping See section 3a to replace relief valve 13 GOLD CGs Gas Fired Water Boiler 3a General piping information If installation is to comply with ASME or Canadian requirements an additional high temperature limit is needed Install control in supply piping between boiler and isolation valve Set second control to minimum 20 F above setpoint of first control Maximum allowable setpoint is 240 F See sec
29. of control module e Place voltmeter leads across the 120 VAC N and 120 VAC H pins of the INDUCER receptacle left column center and right column bottom pins Does the voltmeter indicate 120 VAC No Yes e Try reseating plug in module receptacle and restart e f inducer still does not work replace inducer assembly e Retest e Remove one of the wires connected to the pressure switch e Check continuity across the switch terminals Does the ohmmeter indicate the switch is closed No Yes e Check air pressure switch per manual Section 11 e Replace if necessary e Retest e Replace control module e Retest Part number 550 110 260 0200 Yes d e Wait 5 minutes Is PRESS SWITCH light flashing No Yes Boiler should be in normal operating sequence Observe operation until thermostat is satisfied and inducer has completed its post purge cycle Are vent or combustion air passages blocked No Yes e Clear passages and recycle boiler e Recheck boiler operation GOLD CGs Gas Fired Water Boiler lid Troubleshooting control module lights CHART 4 FLAME amp POWER lights flashing Usually indicates flame sensed when it shouldn t be there WARNING Electrical shock hazard Wherever you see ATURN OFF POWER follow the instructi
30. of the system due to expansion tank waterlogging or undersizing Figure 23 Relief valve typical ai 26032 N 39 GOLD CGs Gas Fired Water Boiler 10b Service amp maint annual start up Review with owner 1 Review the User s Information Manual with the owner 2 Emphasize the need to perform the maintenance schedule specified in the User s Information Manual and in this manual as well 3 Remind the owner of the need to call in a licensed contractor should the boiler or system exhibit any unusual behavior 4 Remind the owner to follow the proper shutdown procedure and to schedule an annual start up at the beginning of the next heating season Cleaning boiler heating surfaces 1 Shut down boiler Follow To Turn Off Gas to Appliance instructions on boiler and Lighting instructions Do not drain boiler unless it will be exposed to freezing temperatures If using antifreeze in system do not drain Follow shutdown procedure Remove venting system connection to boiler Remove top jacket panel Turn back insulation Remove collector box transition assembly Clean sealant from assembly and sections Remove radiation plates hanging between sections zl Si Sr ee Remove burners from base Brush and vacuum burners to remove all dust and lint Verify that all burner ports are free of debris CO Place newspapers in base of boiler to collect soot 9 Clean between section
31. retest box cover and retest i Part number 550 110 260 0200 49 GOLD CGs Gas Fired Water Boiler lid CHART 6 PRESS SWITCH light flashing and POWER light on steady Troubleshooting control module lights Usually indicates pressure switch opened during run cycle May also be caused by wind gusts in excess of 31 mph for non direct vent sidewall vented boilers WARNING Electrical shock hazard Wherever you see ATURN OFF POWER follow the instructions Failure to follow instructions could result in severe personal injury death or substantial property damage e Thermostat should call for heat and appropriate zone valves open Does blower motor operate e Reset boiler control by turning off power at service switch or turning down thermostat for at least 45 seconds No es Remove INDUCER plug Figure 25 Item e page 44 from plug receptacle of control module e Place voltmeter leads across the 120 VAC N and 120 VAC H pins of the INDUCER receptacle left column center and right column bottom pins Does the voltmeter indicate 120 VAC No Yes e Replace inducer assembly e Retest e Remove one of the wires connected to the pressure switch e Check continuity across the switch terminals Does the ohmmeter indicate the switch is closed No Yes e Inspect and check wire harness from control
32. same space Use Figure 3 selecting the appropriate installation conditions Note that the sizing given in Figure 3 applies only to CGs installations with clearances no smaller than shown in Figure 1 page 7 of this manual For smaller clearances regardless of how the air openings are arranged two openings providing free area of 1 square inch per 1 000 Btuh input of all appliances in the space are required Air openings must be sized to handle all appliances and air movers exhaust fans etc using the air supply NOTICE The sizing given in Figure 3 is based on the National Fuel Gas Code ANSI Z223 1 allowing adequate air opening for gravity vented gas appliances Category I The CGs boiler is rated Category III or IV pressurized vent and has different requirements for combustion and ventilation air reflected by the special sizing instructions given in Figure 3 The air openings recommended in Figure 3 will allow adequate ventilation and combustion air provided the boiler room is not subjected to negative pressure due to exhaust fans or other mechanical ventilation devices Refer to the National Fuel Gas Code for dealing with other conditions Louver allowance The free area of openings means the area after reduction for any installed louvers or grilles Be sure to consider this reduction when sizing the air openings Special considerations Tight construction ANSI Z223 1 defines unusually tight construction
33. system piping should include a means of regulating the boiler return water temperature and the system supply temperature such as provided by an injection pumping control Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the system supply temperature is relatively constant DO NOT apply the methods of this manual if the system is equipped with an outdoor reset control Instead provide controls and piping which can regulate the boiler return water temperature at no less than 130 F regardless of system supply temperature Contact your Weil McLain representative for suggested piping and control methods Failure to prevent cold return water temperature to the boiler could cause corrosion damage to the sections or burners resulting in possible severe personal injury death or substantial property damage Part number 550 110 260 0200 Boiler Manual 3f system bypass alternate piping for converted gravity or steam systems From system y A To system X 7b 804 9 Cold 11 H water X Ich fill K 26018 Alternate circulator _ location 10 Figure 13 Piping refrigeration systems A Expansion tank System supply lt _ pk A Shut off Circulator X valve Water chiller 4 2 e GE P Strainer
34. tion 8 Jacket panel interior CGs 3 431 223 291 s i with insulation CGs 4 431 223 292 A Jacketpanel top CGs 3 431 223 334 CGs 5 431 223 293 front CGs 4 431 223 340 CGs 6 431 223 294 CGs 5 431 223 341 P ee CGs 6 431 223 342 9 Jacket panel rear CGs 3 431 223 301 f i T with insulation CGs 4 431 223 302 5 Jacket panel top rear CGs 3 431 223 360 Cep 431 223 303 CGs 4 431 223 361 Cep 431 223 304 Cep 431 223 362 l CGs 6 431 223 363 410 Air inlet fitting 560 907 635 Zi 6 Jacketpanel door CGs 3 431 223 316 d CGs 4 431 223 317 11 Inlet air hose 562 302 573 CGs 5 431 223 318 q j Cep 431 223 319 12 Hose clamp 3 591 850 068 Part number 550 110 260 0200 53 GOLD CGs Gas Fired Water Boiler 12e Replacement parts trim Figure 29 Trim assembly Pressure temperature gauge well fitting is a self closing valve Gauge can be removed from well and replaced without draining the system item Description Manufacturer Manufacturer s Weil McLain number Ge S Part number part number 1 Pressure relief valve ASME 30 PSIG 34 male inlet Conbraco 10 407 10 511 546 920 Watts M330 Pressure relief valve ASME 30 PSIG 34 female inlet Conbraco 10 408 05 511 546 924 Fittings shown are factory installed on boiler Watts 335 2 Combination pressure temperature gauge 2 1 2 short ENFM 4104 510 218 047
35. to the appliance if service is to be performed Remove jacket front panel Turn Gas control knob clockwise to OFF Do not force Replace jacket front panel Part number 550 110 260 0200 Boiler Manual 10a Table 5 Service and maintenance schedules Service and maintenance schedule Service technician see following pages for instructions a vg ke x lt ke Vu l lt Z Z Z lt Inspect e Reported problems e Boiler area e Air openings e Flue gas vent system and air piping e Pilot and main burner flames e Water piping e Boiler heating surfaces e Burners base and inlet air box e Condensate drain system Service e Inducer motor e Oiled bearing circulators Start up e Perform start up per manual Check test e Gas piping e Cold fill and operating pressures e Air vents and air elimination e Limit controls and cutoffs e Expansion tank e Boiler relief valve Review e Review with owner Part number 550 110 260 0200 Owner maintenance see CGs User s Information Manual for instructions Check boiler area Check air openings Check boiler pressure temperature gauge Monthly Check boiler interior piping Check venting system Check air vents Check boiler relief valve Check condensate drain system Check automatic air vents if used Periodically Test low water cutoff if used Clean vent termi
36. 10 260 0200 Control indicator lights non lockout modes FLAME light flashing alone Usually indicates pilot flame was not established within 15 seconds from application of spark Control will flash light but will continue to cycle indefinitely until flame is established or problem is corrected PRESS SWITCH light flashing alone Usually indicates pressure switch opened during the run cycle Troubleshooting the control module See Figure 25 for location of harness plug receptacles and plugs on the control module 43 44 C GOLD CGs Gas Fired Water Boiler Troubleshooting control module continued Figure 25 Control module connections a High voltage to pilot spark electrode White See PS cable 120 VAC N to Des 120 VAC to transformer Red wire to gas valve MV Black 120 VAC H Black wires to thermostat circuit White wire to Blue wire to o 0 gas valve PV Red wires to pressure switch 24 VAC control circuits D r FLAME lt PRESS SWITCH lt LIMIT TSTAT CIRC Ki POWER Indicator lights Model 1107 1 Integrabedt Maler Gorin IT OMAR ant T Faisin Epee gas valve MV PV Yellow wires to limit control and rollout switch Black 120 VAC H Entrance Green ground Chassis Green ground 120 VAC NI S 120 VAC H RR O Black White
37. 20 162 3 Base pan in Base assembly Eegen Zeg CGs 6 550 320 163 E Voie L i 550 320 219 19 Burner 512 200 076 m se assem en _ eg RECKEN E EEN NEE EE e p 20 Burner orifice Natural gas sea level 560 529 077 4 Burner baffle in Base assembly i 5 Base left side nn bly DECH Burner orifice Propane gas sea level 560 529 078 6 Base right side panel in ase assembly a Thermal fuse element 512 050 230 _7 Base back panel in Base assembly 22 Grommet for sealing pilot tubing wiring 591 850 064 8 Base front cross tie assembly in Base assembly El fos opening to Air box wees fg ae SW a Pilot b bracket ___ 480 003 689 23 Inspection p port clear plug 591 491 216 10 Pilot ne eier deer e Heo 24 Hex nut for burner end stud 5 mm 50 320 170 11 Inlet air box front panel in Inlet air box front panel kit Gasket for Air inlet box covers 8 foot length 590 317 400 54 Part number 550 110 260 0200 Boiler Manual a 12d Replacement parts jacket Figure 28 Jacket assembly Item Description Weil McLain item Description Weil McLain kari part number number part number ik cue ape aas eee 7 Jacketcrosstie CGs 3 431 223 326 bottom front CGs 4 431 223 327 2 Jacket panel left side with 431 223 228 Cep 431 223 328 eegene a Cep 431 223 329 3 Jacket panel right side with 431 223 311 al aaa insut
38. 804 ee _ location A Y 9 N10 Cold 11 L water fill KE e fp 26015 UW TW 10 Automatic air vent with diaphragm type expansion tank or connect to tank fitting closed type expansion tank DO NOT use an automatic air vent when using closed type expansion tank It would allow air to leave the system causing waterlogging of the expansion tank 11 Fill valve 12 Diaphragm type or bladder type expansion tank if used For closed type expansion tank pipe from top of air separator to tank fitting as in Figure 5 13 Air separator and automatic vent if used Note that the fill valve must always be connected to the expansion tank regardless of location of expansion tank circulator or air separator 19 GOLD CGs Gas Fired Water Boiler 3e Boiler bypass piping method Temperature gauges 20 Valve adjustment Water piping low temp systems This piping method is called a boiler bypass because part of the circulator flow is bypassed around the boiler through valve 7a This method reduces the flow rate throughout the boiler in order to raise the average water temperature in the boiler enough to prevent flue gas condensation Boiler bypass piping is effective for some boilers including the CGs provided the flow rates are adjusted according to the instructions following Figures 10 and 11 are alternative piping sug
39. GOLD CGs Gas Fired Water Boiler WEIL McLAIN Boiler Manual e Installation e Maintenance e Start Up e Parts ae technician Failure to comply could result in severe personal injury death Z Sen or substantial property damage hb SW DESIGN P k Ke WARNING This manual must only be used by a qualified heating installer service Part No 550 110 260 0200 GOLD CGs Gas Fired Water Boiler D 0 amp How it 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 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 seco
40. R If you cannot reach your gas supplier call the fire department EEE OOPERATING INSTRUCTIONS IS 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 This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Turn Gas control knob clockwise to OFF 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 Turn Gas control knob counterclockwise w to ON Turn on all electric power to the appliance Set thermostat to desired setting 11 If the appliance will not operate follow the instructions To Turn Off Gas To Appliance below and call your service technician or gas supplier 12 Replace jacket front panel 26070 e f a E White Rodgers EE e 36C Gas valve ch A Position indicator e shown in ON position White Rodgers 36E Gas valve Position indicator J I shown in ON position DAS e ke Gas control knob Honeywell VR8204 or VR8304 Gas valve d i ES Position indicator arr iS shown in ON position vs 7 ai Gas control knob DSTO TURN OFF GAS TO THE APPLIANCE M 34 Set the thermostat to lowest setting Turn off all electric power
41. System or zone circulator 5 Zone valve 6 Drain valve 9 Relief valve 10 Automatic air vent with diaphragm type expansion tank or connect to tank fitting closed type expansion tank DO NOT use an automatic Figure 7 Zoning with zone valves return water 130 F or higher pos ZONE 2 p th I e ZNE ma X Gi 1X Xi 5 Xg r H l ot Me gt E i 1 13 6 k FHA 6 1 14 Alternate o circulator _ location A 9 10 Cold 11 vam oo i ml 12 gt 26013 air vent when using closed type expansion tank It would allow air to leave the system causing waterlogging of the expansion tank 11 Fill valve 12 Diaphragm type or bladder type expansion tank if used For closed type expansion tank pipe from top of air separator to tank fitting as in Figure 5 13 Air separator and automatic vent if used Note that the fill valve must always be connected to the expansion tank regardless of location of expansion tank circulator or air separator For systems with possible low return water temperature such as converted gravity systems radiant heating systems and heat pump systems refer to the special piping suggestions of Figures 8 12 as applies Failure to prevent sustained low return water temperature to the boiler could cause corrosion of the boiler sec
42. VAC present there ey Does FLAME light flash now Yes No No Yes y e Check the voltage across l e Verify inlet gas pressure at gas If the wiring from the terminals B and A see e Boiler should be in valve control module to gas Table G page 33 of the normal operating Natural gas 5 0 w c min 14 0 valve is intact replace the gas valve Sequence w c max control module 1 Is 24 VAC present there EE Propane 11 0 w c min 14 0 We No Y until thermostat is satisfied and blower ee has completed its Is gas present at gas valve inlet and ithi post purge cycle veo above ten us e Verify inlet gas pressure at gas valve Natural gas 5 0 w c min 14 0 w c max ATURN OFF POWERA to Propane 11 0 w c min 14 0 w c max boiler at service switch or Is gas present at gas valve inlet and within above range breaker e Contact gas supplier to correct No Yes e Remove air inlet box top pressure or gas supply see Figure 27 page 54 for E location ATURN OFF POWER A io boiler e ATURN OFF POWERA to boiler at service switch or breaker e Verify pilot gas line is not at service switch or breaker s Check flame signal Detach sense lead from igntion control kinked obstructed or damaged e Remove air inlet box cover see Figure 25 item 8 page 44 and is correctly attached
43. Venting Vertical or Sidewall Venting Supplement shipped with the boiler Part number 550 110 260 0200 Boiler Manual 1 Prepare boiler location contamination Air contamination Please review the following information on potential Refer to Table 1 for products and areas which may cause combustion air contamination problems contaminated combustion air If the boiler is installed in any area likely to cause contamination or if products which would contaminate the air cannot be removed you must pipe combustion air to the boiler air intake Contaminated combustion air will damage the boiler resulting in possible severe personal injury death or substantial property damage Do not install CGs boiler in a laundry room or pool facility for example without using ducted outside air These areas will always contain contaminants Table 1 Corrosive contaminants Products to avoid Areas likely to have contaminants Spray cans containing chloro fluorocarbons Dry cleaning laundry areas and establishments Permanent wave solutions Swimming pools Chlorinated waxes cleaners Metal fabrication plants Chlorine based swimming pool chemicals Beauty shops Calcium chloride used for thawing Refrigeration repair shops Sodium chloride used for water softening Photo processing plants Refrigerant leaks Auto body shops Paint or varnish removers Plastic manufacturing plants
44. al air vents located throughout the system i Ifpurge valves are not installed in system open manual air vents in system one at a time beginning with lowest floor Close vent when water squirts out Repeat with remaining vents 4 Open automatic air vent diaphragm type or bladder type expansion tank systems only one turn 5 Open other vents a Starting on the lowest floor open air vents one at a time until water squirts out b Repeat with remaining vents 6 Refill to correct pressure 27 28 la 7b GOLD CGs Gas Fired Water Boiler Start up preparation Inspect system water piping After filling the boiler and system with water inspect all piping throughout the system for leaks If found repair immediately Repeat this inspection after the boiler has been started and the system has heated up Leaks must be repaired at once Failure to do so can damage the boiler resulting in substantial property damage DANGER Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to boiler will occur resulting in substantial property damage continued Inspect base insulation Check to make sure insulation is secure against all four sides of the base If insulation is damaged or displaced do not operate boiler Replace or reposition insulation Failure to replace damaged insulation or reposition insulation can result in a fire haz
45. ance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously e Test for spillage at draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe f After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use Any improper operation of common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 latest edition Correct by resizing to approach the minimum size as determined using the appropriate tables in Part 11 of that code Canadian installations must comply with B149 1 or B149 2 Installation Code CGs special vent system Ventsystem The CGs boiler requires a special vent system designed for pressurized venting Model CGs 3 is rated ANSI Z21 13 Category IV pressurized vent likely to condense in the vent Models CGs 4 5 and 6 are rated Z21 13 Category Ill pressurized vent
46. ard causing severe personal injury death or substantial property damage The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on page 60 of this manual Failure to comply could result in severe personal injury Start up operate boiler Final check before starting boiler Read manual section 9 including the Lighting instructions procedure Figure 21 page 34 Verify the boiler and system are full of water Verify the Start up preparation procedures of section 7a have been completed Start the boiler Follow the Lighting instructions from section 9c to start the boiler See section 7c if boiler fails to start Check system and boiler DANGER Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to boiler will occur resulting in substantial property damage Eliminate all system leaks Continual fresh makeup water will reduce boiler life Minerals can build up in sections reducing heat transfer overheating cast iron and causing section failure Check system piping for leaks If found shut down boiler and repair immediately Vent air from system using manual vents Air in the system will interfere with circulation and cause heat distribution problems and noise Inspect vent system thoroughly for signs of deterioration from corrosion physical damage or sagging In addition Ch
47. as no oxygen barrier a heat exchanger must be used Radiant heating system piping should include a means of regulating the boiler return water temperature and the system supply temperature such as provided by an injection pumping control Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the system supply temperature is relatively constant Do not apply the methods in this manual if the system is equipped with an outdoor reset control Instead provide controls and piping which can regulate the boiler return water temperature at no less than 130 F regardless of system supply temperature Contact your Weil McLain representative for suggested piping and control methods Failure to prevent cold return water temperature to the boiler could cause corrosion damage to the sections or burners resulting in possible severe personal injury death or substantial property damage Part number 550 110 260 0200 Boiler Manual typical piping multiple zone installations Figure 6 Zoning with circulators return water 130 F or higher An ZONE2 p EH oe ZONEI lt an X Di 1X x 2 a a Ei 2 1 Hu 3Y VY KE ee qd See ee 3 ep y A 9 10 Cold 11 A vai 12 26012 1 Boiler isolation balancing valves 2 Flow check valve 3
48. aterials 2 Recommended service clearances See Figure 1 3 Minimum clearances for tight spaces See Figure 2 Figure 1 Recommended clearances for service f ag Figure 3 Minimum clearances for tight spaces Each opening must have free area of 1 square inch per 1 000 Btuh of CGs boiler input Provide 2 fresh air openings 6 from top and 6 from bottom located on wall next to boiler front Part number 550 110 260 0200 Flooring and foundation Flooring The CGs boiler is approved for installation on combustible flooring but must never be installed on carpeting Do not install boiler on carpeting even if foundation is used Fire can result causing severe personal injury death or substantial property damage Foundation Provide a solid brick or minimum 2 inch thick concrete foundation pad if any of the following is true floor can become flooded the boiler mounting area is not level The minimum foundation size is 25 long by Boiler model number Width Inches CGs 3 15 CGs 4 18 CGs 5 21 CGs 6 24 Residential garage installation Precautions Take the following special precautions when installing the boiler in a residential garage If the boiler is located in a residential garage per ANSI 2223 1 paragraph 5 1 9 Mount the boiler a minimum of 18 inches above the floor of the garage to assure the burner and ignition devices will be no less t
49. conds NO i L _ _ 30 sec if boiler not operated for 30 days ft or ON OFF Tf pilot flame is not proven in 15 seconds control module will flash the FLAME light but will continue indefinitely with attempts to light the pilot burner The control module will not lockout on a failure to establish flame It will lockout if line voltage polarity is reversed stray voltage is sensed on thermostat line pressure switch sticks closed or fails to make within 5 minutes or if flame is sensed when it shouldn t be there The boiler will reset after these lockouts Removal of 120 VAC power for at least 45 seconds 26030 Part number 550 110 260 0200 31 GOLD CGs Gas Fired Water Boiler 9b Figure 19 Schematic wiring diagram e The control module is polarity sensitive to the incoming 120 VAC power If polarity is reversed 120 VAC Hot d control will flash the POWER light when powered SERVICE N J E and will not cycle boiler SWITCH e Al contacts shown without power applied e Connector and status light locations orientations ay may vary Wire nuts Black White Plua i g in ee Items not provided Junction box Red boiler left side lt gt AIR PRESSURE L TRANSFORMER a SWITCH J CIRCULATOR Operation wiring diagrams Neutral Gnd Pe alae m l i X i FIELD By H WIRING 2 S l W Ground Se Kat screw 7 ug g s White Green Black B
50. connected to it If connected directly to boiler set for 0 4 amps For other devices refer to manufacturer s specifications Wiring diagram on boiler gives setting for control module and gas valve Also see instructions with thermostat Junction Box furnished 1 Connect 120 VAC power wiring as shown in Figure 15 2 Fused disconnect or service switch 15 amp recommended may be mounted on this box For those installations with local codes which prohibit installation of fused disconnect or service switch on boiler install a 2 x 4 cover plate on the boiler junction box and mount the service switch remotely as required by the code Service c E switch KH not provided l l Ka I Thermostat I or end switch Eo not provides i l l II 4 d l l e Wie po WW l l S J J Thermostat L 7 or end switch Wire nuts not provided Black Black Thermostat leads through jacket left side Part number 550 110 260 0200 Boiler Manual Wa Start up preparation Determine if water treatment is needed Do not use petroleum based cleaning or sealing compounds in boiler system Severe damage to boiler will occur resulting in substantial property damage Eliminate all system leaks Continual fresh makeup water will reduce boiler life Minerals can build up in sections reducing heat transfer overheating cast iron and causing section failure Verify water chemistry Consult local water tr
51. d Inclined manometer with 0 2 w c range 2 Check for 120 VAC minimum 102 VAC to maximum 132 VAC to boiler 3 Make sure thermostat is calling for heat and contacts including appropriate zone controls are closed Check for 24 VAC between thermostat wire nuts and ground Check the following 1 Wire connectors to control module are securely plugged in at module and originating control 2 Air pressure switch hoses are properly and securely plugged in and are not damaged 3 Gas pressures a With boiler off 13 w c maximum natural or propane gas pressure upstream of gas valve b With boiler on e 5 w c natural gas pressure or 11 w c propane gas pressure upstream of gas valve e 3 w c natural gas pressure or 10 w c propane gas pressure downstream tapping on gas valve Can be adjusted by regulator on gas valve VERIFY PROPER OPERATION AFTER SERVICING 41 11b 42 GOLD CGs Gas Fired Water Boiler Troubleshooting air pressure switch Make sure boiler water temperature is 100 F or cooler before starting procedure to obtain appropriate readings NOTICE Check pressure switch setting 1 See Figure 24 and Table 6 2 Remove both air pressure switch hoses from air pressure switch 3 Install tees and tubing as shown in Figure 24 to inclined manometer 4 Turn off gas valve and set thermostat to call for heat Inducer will run but burners will not ignite 5 Check for
52. e 3 page 14 Note 2 138 gt 8 Ez gt 4 ke gt 434 Le rl 5 A e poe lt T 3 s SO ty ae an N SEAN A UI A NOTE 2 28 o 19 t 19 1316 sl C Y Y 12 A La 23 gt 1 26060 LEFT SIDE FRONT RIGHT SIDE Boiler Supply Return Gas Gas A W model tapping tapping connection size manifold size Air inlet Jacket number inches NPT inches NPT Note 3 Note 3 pipe center width inches NPT inches NPT inches inches CGs 3 1 1 Va Va 6 13 CGs 4 1 1 Va Va 8 16 CGs 5 1 1 Va Va 9 19 CGs 6 1 1 Y2 Ya 11 22 Note 3 Gas piping from meter to boiler to be sized per local utility requirements 58 Part number 550 110 260 0200 Boiler Manual 13b Ratings CERTIFIED Lrorgye EPA DOE SAVING THE EARTH SAVING YOUR MONEY Note 5 Table 7 Boiler ratings Boiler DOE 0 2 000 feet 2 000 4 500 feet Net Boiler DOE Vent model Heating 1l B R water Seasonal size number capacity Input Output Input Output ratings content efficiency Btuh Btuh Btuh Btuh Btuh Btuh gallons AFUE Note 1 Note 2 Note 3 Note 5 Note 4 CGs 3 57 000 67 000 57 300 60 300 51 600 50 000 1 5 85 3 3 Note 5 CGs 4 85 000 100 000 85 000 90 000 76 500 74 000 2 1 84 6 oj CGs 5 112 000 133 000 112 400 119 000 100 600 97 000 2
53. e control module Retest Perform start up procedures in boiler manual to verify proper operation instructions e Perform start up procedures in boiler manual to verify proper operation e Boiler should now operate normally e Original flashing FLAME light caused by gas valve not operating properly e See normal sequence of operation Figure 18 page 31 Replace control module Retest Part number 550 110 260 0200 Boiler Manual continued CHART 5 FLAME light flashing and POWER light on steady ALSO Troubleshooting failure to establish main flame WARNING Electrical shock hazard Wherever you see ATURN OFF POWER follow the instructions Failure to follow instructions could result in severe personal injury death or substantial property damage e Are main manual shutoff valve and boiler gas valve open e Is pilot flame visible through inspection port No Yes No Yes a e ATURN OFF POWER to boiler at service switch or breaker e Open main manual shutoff valve and boiler gas valve per Lighting instructions in this manual Wait at least 45 e Check the voltage across terminals C and A of the e Make sure ground wire seconds gas valve see Table G terminal is securely fastened e Turn on power at service switch or breaker Allow boiler to page 33 to control module mounting cycle Is 24
54. e is no longer a voltage reading under any condition in the external thermostat circuit y Boiler should now operate per the normal sequence of operation shown in Figure 18 page 31 No e f no voltage is found under any condition of the external thermostat circuit connect the two boiler thermostat connection leads together or jumper the boiler aquastat T T terminals e Turn off power to the boiler for 1 minute e Turn on power and allow boiler to cycle Do the TSTAT and POWER lights still flash No Yes y e Replace control module e Retest Part number 550 110 260 0200 Boiler Manual continued CHART 3 PRESS SWITCH amp POWER lights flashing Usually indicates pressure switch stuck closed or failed to make within 5 minutes WARNING Electrical shock hazard Wherever you see ATURN OFF POWER A follow the instructions Failure to follow instructions could result in severe personal injury death or substantial property damage e Thermostat should call for heat and appropriate zone valves open e Reset boiler control by turning off power at service switch or turning down thermostat for at least 45 seconds Does inducer motor operate No d Does inducer motor operate No e Wait 45 seconds Yes es Remove INDUCER plug Figure 25 Item e page 44 from plug receptacle
55. eatment companies for unusually hard water areas above 7 grains hardness or low pH water conditions below 7 0 Boiler water pH of 7 0 to 8 5 is recommended Freeze protection when used Use antifreeze made especially for hydronic systems Inhibited propylene glycol is recommended Do not use ethylene glycol automotive or undiluted antifreeze Severe personal injury or death can result 1 Determine antifreeze quantity according to system water content Boiler water content is listed on page 59 Remember to include expansion tank water content 2 Follow antifreeze manufacturer s instructions A 50 solution of propylene glycol water provides maximum protection to about 30 F 4 Local codes may require back flow preventer or actual disconnect from city water supply 5 When using antifreeze in a system with automatic fill install a water meter to monitor water makeup Glycol will leak before the water begins to leak causing glycol level to drop Added water will dilute the antifreeze reducing the freeze protection level Check for gas leaks WARNING Before starting the boiler and during initial operation smell near the floor and around the boiler for gas odorant or any unusual odor Do not proceed with start up if there is any indication of a gas leak Repair any leak at once Propane boilers only Your propane supplier mixes an odorant with the propane to make its presence de
56. eck for gas tight seal at every connection and seam Venting system must be sealed gas tight to prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death Part number 550 110 260 0200 7b VG Part number 550 110 Boiler Manual Start up operate boiler continued 4 Check around the boiler for gas odor following the procedure of section 7a of this manual If you discover evidence of any gas leak shut down the boiler at once Find the leak source with bubble test and repair immediately Do not start boiler again until corrected Failure to comply could result in severe personal injury death or substantial property damage Check burner flames View pilot and main flames through the inspection port in the Air inlet box front cover Pilot burner flame Proper pilot flame characteristics see Figure 16 1 Blue flame 2 Inner cone engulfing pilot flame sensor 3 Pilot flame sensor glowing cherry red Improper pilot flame characteristics 1 Overfired Large flame lifting or blowing past pilot flame sensor 2 Underfired Small flame Inner cone not engulfing pilot flame sensor 3 Lack of primary air Yellow flame tip 4 Incorrectly heated pilot flame sensor Main burner flame Proper main burner flame characteristics see Figure 17 1 Yellow orange streaks may appear caused by dust Improper main burner fla
57. erty damage Part number 550 110 260 0200 3b Boiler Manual Water piping single zone system Expansion tank Diaphragm type or bladder type expansion tank Figure 4 1 Ensure expansion tank size will handle boiler and system water volume and temperature Tank must be located in boiler return piping as close to boiler as possible before inlet side of circulator See tank manufacturer s instructions for details 2 Install an automatic air vent in air vent tapping as shown CAUTION Closed type expansion tank Figure 5 1 Ensure expansion tank size will handle boiler and system water volume and temperature See tank manufacturer s instructions for details 2 Connect tank to NPT tapping located behind supply outlet using 1 2 NPT piping Pitch any horizontal piping up towards tank 1 inch per 5 feet of piping Undersized expansion tanks cause system water to be lost from relief valve and makeup water to be added through fill valve Eventual section failure can result Use Figure 4 or Figure 5 only for single zone systems designed for return water at least 130 F For systems with low return water temperature possible such as converted gravity systems and radiant heating systems refer to the special piping suggestions of pages 18 23 Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners resulting in severe personal
58. gers 36E 2 1 3 White Rodgers 36C 2 4 1 3 Terminals 2 4 are factory jumpered on the White Rodgers 36C gas valve All wiring must be installed in accordance with A U S A N E C And any other national state or local code requirements B Canada C S A C22 1 C E C Part 1 and any other national provincial or local code require ments Pilot lead wires are not field replaceable Replace pi lot assembly if necessary If any of the original wire as supplied with the ap pliance must be replaced use minimum 105 C wire or equivalent Exception wires to a rollout TFE must be 200 C or equivalent Thermostat anticipator setting single zone see Table G for anticipator setting depending on which gas valve is installed in boiler For multiple zoning use either zone valves or circulators Refer to the component manufac turer s instructions and this manual for applica tion and wiring suggestions Refer to control component instructions packed with the boiler for application information Wire any additional limit controls low water cut off additional high limit etc in series with boiler limit control as shown Part number 550 110 260 0200 THERMOSTAT 3K PILOT GAS VALVE A e R Tstat Circ RY Limit ROLLOUT WATER TEMP TFE LIMIT SWITCH Additional KN limits note 7 AIR PRESSURE SWITCH MAIN GAS VALVE See Table G
59. gestions for converted gravity large water content or steam systems or radiant heating system for use when primary secondary piping can t be applied Figure 12 is another alternative using system bypass in place of boiler bypass piping Figure 12 however is not suitable for radiant heating applications because it does not protect the radiant system from possible high water temperature Boiler bypass piping keeps system flow rate as high as possible and temperature drop as low as possible helping to equalize the building heat distribution Gauge 4a is optional if the bypass valves will be adjusted using cold or room temperature return water to the boiler When setting the valves without gauge 4a installed using cold or room temperature water assume the return water temperature to be 60 F Set the valves so gauge 8 reads at least 120 F Gauge 4b is optional on converted gravity systems but required on radiant heating systems to display the water temperature being supplied to the radiant tubing Gauge 8 is required on all systems to assure reliable adjustment of the bypass valves The boiler mounted temperature pressure gauge can be used if a separate temperature gauge is not installed 1 Start with valve 7a fully closed and 7b fully open 2 Gradually open valve 7a while closing valve 7b until the temperature at gauge 8 reads 60 F higher than gauge 4a A minimum 60 F temperature rise through the boiler assures
60. h limit 30 differential with well Honeywell L4080D1036 510 312 250 e WE P R White Rodgers 11B81 3 0 10 Inducer fan assembly kit includes inducer fan assembly gasket and nuts 381 356 499 11 Gasket inducer ae le 590 317 627 Part number 550 110 260 0200 53 GOLD CGs Gas Fired Water Boiler al 12c Replacement parts base Figure 27 Base assembly Item Description Weil McLain item Description Weil McLain e part number Lee part number Base insulation kit os 381 356 515 12 Inlet air box front panel gasket Use Gasket kit ee eecht Gase tee 1 Inlet air box top panel in Inlet air box top panel kit between block assembly and base CGs 6 381 356 518 14 Inlet air box top panel gasket Use Gasket kit Lk EE we NETAN SE AE 15 Manifold per size CGs 3 591 126 722 5 6 7 8 11 13 22 and 23 plus CGs 5 381 356 524 Gi 2 SE Geescht Air box gaskets and CGs 6 381 356 525 CGs 6 591 126 725 Inlet air box top panel kit CGs3 381 356501 16 Manifold mounting gasket 590 317 406 N includes items 13 and 14 carg Seo 17 Burner mounting panel cosg egen CGs 6 381 356 504 CGs 5 450 003 692 inlet air box front panel kit CGs 3 381 356 508 CGs 6 450 003 693 includes items 11 12 and 23 CGs 4 381 356 509 EEC IAr egen 550 320160 spacer strip CGs 3 550 320 160 CGs 5 381 356 510 CGs 4 550 320 161 Cep 381 356 511 CGs 5 550 3
61. han 18 inches above the floor Locate or protect the boiler so it cannot be damaged by a moving vehicle le GOLD CGs Gas Fired Water Boiler Prepare boiler location vent system Removing from existing vent Do not install the CGs into a common vent with any other appliance This will cause flue gas spillage or appliance malfunction resulting in possible severe personal injury death or substantial property damage Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death When removing boiler from existing common ventsystem At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion or other deficiencies which could cause an unsafe condition c Test vent system Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appli
62. he manifold 4 Apply a small amount of pipe dope to each of the new orifices and install in the manifold using a 7A open end wrench Make sure the orifices are aligned correctly not cross threaded in the manifold tappings Use only pipe dope compatible with propane gas even if boiler is to be operated on natural gas Failure to comply could result in severe personal injury death or substantial property damage 5 Carefully replace the inlet air box top panel making sure the gasket is in place will seal all around the perimeter 6 Follow the check out procedure section 8 page 30 to assure the boiler is now operating properly after orifices are replaced Location Natural gas Propane gas 0 2 000 ft over 2 000 ft 0 2 000 ft over 2 000 ft U S 2 70 mm Note 1 1 65 mm Note 1 0 2 000 ft 2 000 4 500 0 2 000 ft 2 000 4 500 Canada 2 70 mm 38 1 65 mm 53 Note 1 For elevations above 2 000 feet contact your local Weil McLain sales office for details Part number 550 110 260 0200 Boiler Manual 2b Prepare boiler pressure test Perform hydrostatic pressure test Part number 550 110 260 0200 Pressure test boiler before attaching water or gas piping except as noted below or electrical supply Prepare boiler for test 1 2 Remove the shipping nipple from CGs supply tapping and remove the boiler relief valve Temporarily plug the relief valve tapping with a 34
63. is now in the off cycle Repeat steps 1 through 6 several times to verify operation Return the thermostat to normal setting Set thermostat heat anticipator setting to 0 4 amps adjusted for gas valve and control current Figure 18 Control module sequence of operation status light indications if any of the following occurs 1 hour waiting period Opening and closing of thermostat circuit Steps Call for POWER TSTAT LIMIT PRESS FLAME Timing heat CIRC SWITCH Following step 8 cycle goes back to step 1 f f f 1 Standb SCH la N PN N pa Waiting for call for heat NO 2 Call for heat ze WR j Circulator on YES i t L _ _ Blower on 3 Limit circuit be whe f D E Limit controls closed YES i fi L L Block switch contacts closed 4 Pressure circuit ae Ae Ae Pressure switch contacts closed YES i t 35 sec Prepurge for 30 seconds 5 Pilot fama proven as valve open le Ne Ae dek Ae Pilot remains on YES fi ft ft 15 sec Boiler producing heat 6 Limit cycle Ze ei as Limit circuit open YES fi ft L WR CC Es Gas valve closed 7 Flame outage ck Abi alg EAs 8 Flame out YES fi ft ZS CC Boiler recycles 8 Thermostat satisfied che Js he ENPA S Circulator off NO fi ZS _ 15 sec Blower postpurge 9 Circulator exercise routine ale oS pN G i Circulator turns on for 30 se
64. jacket when required by local codes or utility requirements d In Canada When using manual main shutoff valve it must be identified by the installer Figure 14 Gas supply piping e Manual main shutoff gas valve when required Ground joint union when required 26020 Part number 550 110 260 0200 a Boiler Manual Gas piping continued Support piping with hangers not by boiler or its accessories Purge all air from gas supply piping Before placing boiler in operation check boiler and its gas connection for leaks Natural Gas 1 Refer to Table 4 for pipe length and diameter Base on rated boiler input divide by 1 000 to obtain cubic feet per hour Table 4 is only for gas with specific gravity 0 60 with a pressure drop through the gas piping of 0 30 w c For additional gas pipe sizing information refer to ANSI Z223 1 or B149 1 or B149 2 for Canadian installations Inlet pressure required at gas valve inlet a Close manual main shutoff valve during any pressure testing at less than 13 w c b Disconnect boiler and gas valve from gas 2 supply piping during any pressure testing greater than 13 w c e Maximum 13 w c e Minimum 5 w c n e Manifold gas pressure 3 5 w c Do not check for gas leaks with an open flame use bubble test 3 Failure to use bubble test or check for gas leaks can cause severe personal injury death or substantial
65. lack Jacket opening boiler left side Fave press sw wm tTstaticirc Power WATER TEMPERATURE Honeywell VR8204 shown LIMIT SWITCH R e ges sl went A Additional Tee w limits KE KN J 1 f PILOT R if used if Se 1 A BURNER g note 7 gon XOK Sech U Terminal block 71034 BLOWER MOTOR GAS VALVE See Table G 32 Part number 550 110 260 0200 Boiler Manual Figure 20 Ladder wiring diagram Electrical shock hazard can cause Hot Neutral O severe injury or death Disconnect SERVICE 120 VAC ower before installing or servicing 3 i SWITCH NOTICE All contacts are shown without power K applied Legend for ladder wiring diagram INDUCER MOTOR CONTROL MODULE 120 VAC SECTION 20 VAC field wiring zs Low voltage field wiring 120 VAC factory wiring HIGH Low voltage factory wiring VOLTAGE High voltage spark ignition wiring PILOT IGNITION ELECTRODE Ground connectors Table G Gas valve terminals and anticipator settings Anticipator amps 0 6 0 8 0 64 0 7 Gas valve A B Tei Honeywell VR8204 MV PV MV PV Honeywell VR8304 MV PV MV PV White Rod
66. les representative closed e See Figure 18 page 31 N v Check rollout switch for normal sequence of 9 es continuity is switch operation pl closed e Wait for boiler water to cool to temperature 20 to 30 F No Yes lower than temperature set on limit switch e Are limit switch contacts closed e Replace rollout switch No Yes Y DANGER e Check any other e Boiler water temperature exceeded If rollout thermal fuse element has limit controls wired setting on limit switch with thermostat opened determine cause and into the limit Febi calling for heat Boiler is OK See normal correct condition Failure to do so circuit If all are li SC h sequence of operation Figure 18 p 31 will cause severe personal injury OK then replace z SC Sg Ch e Also check setting on limit switch should death or substantial property control module ee be above 140 F damage e Retest Part number 550 110 260 0200 51 52 GOLD CGs Gas Fired Water Boiler 12a Replacement parts Section assembly ee ENEE ENEE ENEE enen 5S Base assembly zeiesggiapeekieegagigeuietgegie Egger eeeee 54 Jacket assembly eneen ek ENEE Ek EK Ee ven wen OD Trim assembly see ENN ENEE ENNEN ENEE unn DG Gas control assembly ee ENNEN ENEE ennen BI NOTICE Replacement parts must be purchased through a local Weil McLain distributor When ordering specify boiler model and size and include descrip
67. m type expansion tank or connect to tank fitting closed type expansion tank DO NOT use an automatic air vent when using closed type expansion tank It would allow air to leave the system causing waterlogging of the expansion tank 11 Fill valve h 12 Diaphragm type or bladder type expansion tank if used For closed type expansion tank pipe from top of air separator to tank fitting as in Figure 5 13 Air separator and automatic vent if used Note that the fill valve must always be connected to the expansion tank regardless of location of expansion tank circulator or air separator 21 GOLD CGs Gas Fired Water Boiler 3f System bypass piping method Valve adjustment Water piping low temp systems This piping method is called a system bypass because part of the circulator flow bypasses the system through valve 7a This bypassed hot water from the boiler outlet mixes with cooler system return water temperature in order to provide minimum 130 F return water to the boiler Valve 7b will most often be full open but may need to be slightly closed on some low pressure drop systems in order to cause enough flow through valve 7a Figure 12 is an alternative piping method that provides return water temperature control for boilers installed on converted gravity systems large water content or steam systems Do not apply the piping of Figure 12 on radiant heating systems It provides no method regula
68. me characteristics 1 Overfired Large flames 2 Underfired Small flames 3 Lack of primary air Yellow tipping on flames sooting will occur Figure 16 Typical pilot burner flame Spark cone electrode Pilot flame sensor 26023 Figure 17 Typical main burner flame Transparent blue flame Start up if boiler doesn t start Check for 1 Loose connections blown fuse or service switch off 2 High limit switch set below boiler water temperature 3 Thermostat set below room temperature 260 0200 4 Gas not turned on at meter or boiler 5 Incoming gas pressure less than 5 w c for natural gas 11 w c for propane gas If none of the above corrects the problem refer to Troubleshooting section 11 of this manual 29 COOU O O GOLD CGs Gas Fired Water Boiler 8 Boiler and heat distribution units filled with water Automatic air vent if used open one full turn Air purged from system Air purged from gas piping Piping checked for leaks Correctly sized manifold orifices installed Refer to manual section 2a to check size and fuel type Correctly sized manifold orifices must be used Failure to do so will cause severe personal injury death or substantial property damage Followed operating instructions on boiler or in manual section 9 for proper start up Proper burner flame observed Refer to Check burner flame manual section 7b Test limit con
69. module to pressure switch s Reseat connector in control module receptacle e f harness is intact and Yes e Wait 5 minutes Is PRESS SWITCH light flashing No Boiler should be in normal operating sequence e Observe operation until thermostat is satisfied and inducer has completed its post purge cycle Are vent or combustion air passages blocked No Yes properly seated but problem persists replace control module Replace if necessary Retest e Retest e Check air pressure switch per manual Section 11 Clear passages and recycle boiler Recheck boiler operation Part number 550 110 260 0200 Boiler Manual continued CHART 7 Insufficient heat or no heat to system POWER light on steady Electrical shock hazard Wherever you see ATURN OFF POWER follow the instructions Failure to follow instructions could result in severe personal injury death or substantial property damage e Has it been at least 5 minutes since setting thermostat to gt Is boiler System circulator operating call for heat If not wait 5 minutes Is system heating e ls thermostat set to call for heat Remove thermostat No Yes wires at
70. nation air intake screens Every 6 months Oil inducer motor Operate relief valve End of season Shut down procedure Follow the Service and maintenance procedures given throughout this manual and in component 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 35 10b 36 GOLD CGs Gas Fired Water Boiler Service amp maintenance annual start up 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 in Table 5 and explained on the following pages must be performed to assure maximum boiler efficiency and reliability Failure to service and maintain the boiler and system could result in equipment failure Inspect Reported problems Inspect any problems reported by owner and correct before proceeding Boiler area 1 Verify that boiler area is free of any combustible materials gasoline and other flammable vapors and liquids Verify that boiler area and air intake is free of any of the contaminants listed on page 9 of this manual If any of these are present in the boiler intake air vicinity they m
71. nd 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 see page 43 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 The circulator is shipped loose and can be mounted on either the boiler supply or return piping The factory installed circulator wiring harness provides ample length for either location 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 turn off Other boiler components a supply to system f pressure tem
72. ntinual fresh makeup water will reduce boiler life Mineral buildup 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 prevent makeup water Do not add cold water to hot boiler Thermal shock can cause sections to crack Glycol potential fire hazard All glycol is flammable when exposed to high temperatures If glycol is allowed to accumulate in or around the boiler or any other potential ignition source a fire can develop In order to prevent potential severe personal injury death or substantial property damage from fire and or structural damage Never store glycol of any kind near the boiler or any potential ignition source Monitor and inspect the system and boiler regularly for leakage Repair any leaks immediately to prevent possible accumulation of glycol Never use automotive antifreeze or ethylene glycol in the system Using these glycols can lead to hazardous leakage of glycol in the boiler system GOLD CGs Gas Fired Water Boiler 1 a Prepare boiler location codes amp checklist Installations must follow these codes Before locating the boiler check the following Local state provincial and national codes laws regulations and ordinances National Fuel Gas Code ANSI Z223 1 latest edition Standard for Controls and Safety Device
73. ntracts as the water cools Tanks may be open closed or diaphragm or bladder type See section 3 of this manual for suggested best location of expansion tanks and air eliminators Open type located above highest radiator or baseboard unit usually in the attic or closet Has a gauge glass and overflow pipe to a drain Closed type welded gas tight and located above boiler Tank is partially filled with water leaving an air cushion for expansion e Make sure this type of tank is fitted with a tank fitting such as the B amp G Tank Trol or Taco Taco Trol This fitting reduces gravity Part number 550 110 260 0200 Boiler Manual LJ Check test circulation of air saturated tank water back to the system and prevents the air from bubbling up through the water as it returns from the system Do not use automatic air vents in systems with closed type tanks The air will escape from the system instead of returning to the tank Eventually the tank will waterlog and no longer control pressurization The boiler relief valve will weep frequently Diaphragm or bladder type welded gas tight with a rubber membrane to separate the tank pressurizing air and the water May be located at any point in the system but most often found near the boiler Systems with this type of expansion tank require at least one automatic air vent preferably located on top of an air eliminator as shown in examples in manual section 3
74. o highest setting and verify boiler goes through normal start up cycle Lower to lowest setting and verify boiler goes off Measure natural gas input a Operate boiler 10 minutes b Turn off other appliances c At natural gas meter measure time in seconds required to use one cubic foot of gas d Calculate gas input 3600 x 1000 number of seconds from step e e Btuh calculated should approximate input rating on boiler rating label Btuh Check manifold gas pressure by connecting manometer to downstream test tapping on main gas valve Manifold pressure for natural gas should be 3 5 w c and for propane gas should be 10 w c Observe several operating cycles for proper operation Set room thermostat to desired room temperature Fill in Installation and service certificate below Review all instructions shipped with this boiler with owner or maintenance person Return instructions to envelope and give to owner or place in pocket inside front panel in boiler Boiler model Measured Btuh input Installation and service certificate Series Installer 30 CP number Date installed 1 Installation instructions have been followed LI Check out sequence has been performed LJ Above information is certified to be correct 1 Information received and left with owner maintenance person company address phone installer s signature Part number 550 110 260 0200 Boiler Man
75. ocation 3 Remove crate 4 Remove boiler from pallet Do not drop boiler or bump jacket on floor or pallet Damage to boiler can result NOTICE a Tilt left side of boiler up and place a board under left legs b Tilt boiler the other way and place a board under right legs c Slide boiler backward off pallet and into position 5 Check level a Shim legs if necessary b Do not alter legs Inspect orifices and burners 1 Remove front jacket door Remove inlet air box top panel see Figure 27 item 13 page 54 2 Check for correctly sized manifold orifices See Table 2 for sizing The orifice size is stamped on the orifice spud barrel Correctly sized manifold orifices must be used Failure to do so will result in severe personal injury Table 3 Manifold orifice sizing death or substantial property damage 3 Reinstall inlet air box top panel Inlet air box top panel must be in position during boiler operation Failure to do so could result in severe personal injury death or substantial property damage Orifice replacement procedure when required 1 Remove the screws securing the inlet air box top panel 2 Remove inlet air box top panel and inspect the fiber gasket Verify the gasket is in good condition and can seal around the complete perimeter of the air box Replace the gasket if necessary 3 Using a Ae open end wrench remove the burner orifices from t
76. ons Failure to follow instructions could result in severe personal injury death or substantial property damage Are manual main shutoff valve and gas valve open No Yes Leave main manual gas valve closed Turn off power to boiler at service switch or breaker Wait at least 45 seconds Turn on power to boiler manual Figure 21 page 34 Restart boiler following Lighting instructions in this Do FLAME and POWER lights still flash Turn off power to the boiler at service switch or breaker Wait at least 45 seconds Turn on power to boiler No Yes gt Is pilot burning during prepurge period Restart boiler following Lighting instructions in this manual Figure 21 page 34 e Look through the pilot inspection port in front of air inlet box to see if the pilot is burning during the prepurge period first 30 seconds of operation Replace control module Retest No Yes Allow boiler to continue cycling Are FLAME amp POWER lights flashing e Replace gas valve e Retest boiler Are FLAME and POWER lights flashing No Yes No Yes l e ATURN OFF POWERA to boiler at service switch or breaker e Open main manual gas D valve e Turn on power to boiler at service switch or breaker e Restart boiler per lighting Boiler may now be e operating normally Replac
77. or on boiler except for primary secondary piping Install isolation balancing valves to adjust flow to distribute heat to all zones aa a a Install and wire a separate relay for each zone circulator Install isolation balancing valves to adjust flow to distribute heat to all zones 2 Provide a separate 24 volt transformer to power the zone valves Size the transformer to handle the total rated load of all connected zone valves Converted gravity or steam systems Whenever possible use the primary secondary piping shown in Figures 8 or 9 on page 19 This piping design allows changing boiler flow rate without affecting primary circuit flow rate If Figures 8 or 9 cannot be used use the boiler bypass piping shown in Figure 10 or Figure 11 on page 21 You can also use the piping shown in Figure 12 on page 23 system bypass if the reduced flow rate in the heating system will not cause heat distribution problems Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners resulting in severe personal injury death or substantial property damage Radiant heating systems Preferably use primary secondary piping as shown in Figures 8 or 9 on page 19 Alternatively use the method of either Figure 10 or Figure 11 on page 21 Do not use the piping of Figure 12 system bypass because this method does not control radiant system supply temperature If radiant system tubing h
78. perature gauge k pilot burner and bracket b return from system g relief valve not visible l stainless steel burners e combustion air inlet h air vent connection m cast iron boiler sections flue outlet i flame rollout switch n flue collector gas valve j air inlet box o junction box Part number 550 110 260 0200 Fired Induced Draft Water Boiler Boiler Manual GOLD CGs Gas WA a d E A AN wem y THE g ki e wi e EI P oT aA L Buet KS NM G Sit ei d d SR Y d Gy A e OG fei N d FA fi 3 WW H Ze ty iad ei P Bai A p A d E bs Bes j f Z TING Sec Part number 550 110 260 0200 GOLD CGs Gas Fired Water Boiler Contents HOW it works 1 00 2 eeeeeeeeeee eee eeeeeeeeeeeeeeeeeeeseeeeaaaaaeeeeeeeeees 2 3 Ha rd definition S ssssseisscsrccersriraissnnai 4 Please read before proceeding 5 1 Prepare boiler location REENEN EEN 6 11 2 Prepare Doller ssis 12 13 3 Water piping EE 14 23 4 Venting D combustion aif cccceeeeeeeeeeeeeeeeeeeeeees 24 5 Gas piping EEN 24 25 6 Field wiring ccnnnsncncadicsddddddidddiiidbisinddddddddddddddiceceoncooncassnan 26 PAA E TM 27 29 8 Check out procedure REENEN 30 9 EE 31 34 10 Service and maintenance een 35 40 11 Troubleshooting ic cessscsssisceseccsemesssssnssssssnonesssoanbiuns 41 51 12 Replacement patts ccccceccsseeeeeseeeeeeeeeeeeaees 52 57 13 Dimensions and ratings NEEN 58 59 Hazard definitions
79. property damage Install 100 lockup gas pressure regulator in supply line if inlet pressure exceeds 13 w c Adjust for 13 w c maximum Propane Gas 1 Contact gas supplier to size pipes tanks and 100 5 Use pipe dope compatible with propane gases lockup gas pressure regulator Apply sparingly only to male threads of pipe joints 96 hal pipe dope doesnot Backa dow 2 Adjust propane supply regulator provided by gas supplier for 13 w c maximum pressure 3 Inlet pressure required at gas valve inlet Failure to apply pipe dope as detailed above can result in severe personal injury death or substantial property damage e Maximum 13 w c e Minimum 11 w c Manifold gas pressure 10 w c Table 4 Pipe capacity for 0 60 specific gravity natural gas Gas pipe EEN length een V 34 d 1 14 10 132 278 520 1050 1600 20 92 190 350 730 1100 30 73 152 285 590 860 40 63 130 245 500 760 50 56 115 215 440 670 75 45 93 175 360 545 100 38 79 150 305 460 150 31 64 120 250 380 Part number 550 110 260 0200 25 GOLD CGs Gas Fired Water Boiler 6 NOTICE Figure 15 Field wiring connections service switch and thermostat or end switch provided by installer NOTICE The CGs control module is polarity sensitive The hot and neutral wires must be connected to the correct leads A flashing POWER ligh
80. r will not start if this contact is open and will shut down should it open during operation Part number 550 110 260 0200 Boiler Manual Figure 3 Sizing air openings for CGs installations Apply this table only clearances no smalle Room Air Openings Required area of the air openings given in this table are free area after the correction for louver obstruction See Exception below to installations with r than those shown in Direct exhaust vent installation CGs using room air for combustion Direct vent installation Other appliances combustion air piped to CGs Combustion air piping Other appliances Combustion air piping A Air from Inside each opening each opening each opening Figure 1 page 7 of this manual O SR CH OJ For installations with clearances less than EES CGs EES CGs shown in Figure 1 page 7 of this manual provide 2 openings each with 1 square inch l J l l E of free area per 1 000 Btuh of total input of Room shared CGs alone Room shared CGs alone all appliances with other appliances in room with other appliances in room 2 Openings 2 Openings 2 Openings NO Openings are needed provided
81. s Fired Water Boiler Boiler Manual Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or base insulation panels in this product contain ceramic fiber materials Ceramic fibers can be converted to cristobalite in very high temperature applications The International Agency for Research on Cancer IARC has concluded Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Group 1 E Avoid breathing dust and contact with skin and eyes Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written Other types of respirators may be needed depending on the job site conditions Current NIOSH recommendations can be found on the NIOSH web site at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this web site Wear long sleeved loose fitting clothing gloves and eye protection E Apply enough water to the combustion chamber lining or base insulation to prevent airborne dust E Remove combustion chamber lining or base insulation from the boiler and place it in a plastic bag for disposal E Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid E Eye
82. s for Automatically Fired Boilers ANSI ASME CSD 1 when required National Electrical Code For Canada only B149 1 or B149 2 Installation Code CSA C22 1 Canadian Electrical Code Part 1 and any local codes NOTICE The CGs boiler gas manifold and controls met safe lighting and other performance criteria when boiler underwent tests specified in ANSI Z21 13 latest edition Check for nearby connection to System water piping Venting connections Gas supply piping Electrical power Check area around boiler Remove any combustible materials gasoline and other flammable liquids Failure to keep boiler area clear and free of combustible materials gasoline and other flammable liquids and vapors can result in severe personal injury death or substantial property damage Boiler must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service If new boiler will replace existing boiler check for and correct system problems such as 1 System leaks causing oxygen corrosion or section cracks from hard water deposits 2 Incorrectly sized expansion tank 3 Lack of antifreeze in boiler water causing system and boiler to freeze and leak Part number 550 110 260 0200 1b Boiler Manual Prepare boiler location clearances Provide the following clearances 1 Hot water pipes at least 12 from combustible m
83. s install the system fill connection at the same point as the expansion tank connection to the system Figures 4 and 5 show typical near boiler piping connections System water piping See Figure 4 diaphragm type or bladder type expansion tank or Figure 5 closed type expansion tank on page 15 and Table 3 below for near boiler and single zone systems designed for return water at least 130 F See pages 16 17 to complete multiple zone piping or pages 18 23 to complete piping for radiant heating systems or converted gravity systems Refer to page 23 for boilers used with refrigeration systems Table 3 Water pipe size based on 20 F rise Boiler To From model system system number CGs 3 1 1 CGs 4 1 kb CGs 5 1 1 CGs 6 1 1 Note Circulator flange supplied with boiler is same size as recommended piping above Install boiler such that Chilled medium if used is piped in parallel with heating boiler Use appropriate valves to prevent chilled medium from entering boiler Consult I B R Installation and Piping Guides If boiler is connected to heating coils located in air handling units where they can be exposed to refrigerated air use flow control valves or other automatic means to prevent gravity circulation during cooling cycle Circulation of cold water through the boiler could result in damage to the heat exchanger causing possible severe personal injury death or substantial prop
84. s with wire flue brush 10 Remove newspaper and soot Vacuum or brush base and surrounding area 11 Reinstall radiation plates 12 Replace collector box transition assembly Seal with sealant Obtain gas tight seal to prevent flue gas spillage and carbon monoxide emissions resulting in severe personal injury or death 13 Replace insulation and jacket top panel 14 Start up boiler following section 7 of this manual and the boiler Lighting instructions Excessive sooting indicates improper gas combustion If found check for proper combustion and make any necessary adjustments The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on page 60 of this manual Failure to comply could result in severe personal injury Part number 550 110 260 0200 Boiler Manual lla Part number 550 110 260 0200 Troubleshooting procedure Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Never jumper bypass rollout thermal fuse element or any other device except for momentary testing as outlined in Troubleshooting Charts Severe personal injury death or substantial property damage can result Before troubleshooting 1 Have the following items a Voltmeter that can check 120 VAC and 24 VAC b Microammeter with a minimum scale range of 0 25 c Continuity checker
85. same size as the valve discharge connection throughout its entire length Discharge line must pitch downward from the valve and terminate at least 6 above the floor drain where any discharge will be clearly visible The discharge line shall terminate plain not threaded with a material serviceable for temperatures of 375 F or greater e Do not pipe the discharge to any place where freezing could occur e No shutoff valve shall be installed between the relief valve and boiler or in the discharge line Do not plug or place any obstruction in the discharge line e Failure to comply with the above guidelines could result in failure of the relief valve to operate resulting in possibility of severe personal injury death or substantial property damage Test the operation of the valve after filling and pressurizing system by lifting the lever Make sure the valve discharges freely If the valve fails to operate correctly replace it with a new relief valve 14 Water piping general information Circulator The circulator is shipped loose wiring pre attached to boiler to allow you to locate it either in the return or supply piping as desired See page 3 for a typical installation Pipe the expansion tank to the suction side of the circulator whenever possible Install an air separator in the supply piping Connect the expansion tank to the air separator only if the separator is on the suction side of the circulator Alway
86. t usually indicates reversed polarity of 120 VAC lead wires 26 Field wiring For your safety turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard Failure to do so can cause severe personal injury or death Wiring must be N E C Class 1 If original wiring as supplied with boiler must be replaced use only type 105 C wire or equivalent Boiler must be electrically grounded as required by National Electrical Code ANSI NFPA 70 latest edition Electrical installation must comply with 1 National Electrical Code and any other national state provincial or local codes or regulations 2 In Canada CSA C22 1 Canadian Electrical Code Part 1 and any local codes l 120 VAC ki I Hot Neutral l l I I D E WI Service 5 switch D l not provided De EI l i l H La 7 D E 3 S D Junction box boiler left side n l l l l l l Ground screw Green 26021 Wiring connections Boiler is shipped with controls completely wired Thermostat 1 Connect thermostat as shown on wiring diagram on boiler 2 Install on inside wall away from influences of drafts hot or cold water pipes lighting fixtures television sunrays or fireplaces 3 If thermostat has a heat anticipator set heat anticipator in thermostat to match power requirements of equipment
87. tectable In some instances the odorant can fade and the gas may no longer have an odor Before start up and periodically thereafter have the propane supplier verify the correct odorant level in the gas Part number 550 110 260 0200 Fill the system with water 1 Close manual and automatic air vents and boiler drain cock 2 Fill to correct system pressure Correct pressure will vary with each application Typical cold water fill pressure for a residential system is 12 psi 3 Purge air from system a Connect a hose to the purge valve see drain valves item 6 in suggested piping diagrams on pages 17 through 21 Figure 6 through Figure 11 Route hose to an area where water can drain and be seen b Close the boiler or system isolation valve between the purge valve and fill connection to the system c Close zone isolation valves d Open quick fill valve on cold water makeup line Open purge valve L One zone at a time open the isolation valves Allow water to run through the zone pushing out the air Run until no noticeable air flow is present Close the zone isolation valves and proceed with the next zone Follow this procedure until all zones are purged g Close the quick fill water valve and purge valve and remove the hose Open all isolation valves Watch that system pressure rises to correct cold fill pressure h After the system has operated for a while eliminate any residual air by using the manu
88. the connector box between flue collector and inducer as shown in Figure 24 Part number 550 110 260 0200 lle Boiler Manual Troubleshooting control module Make sure ground wiring is installed per wiring diagram Good grounding is extremely important for proper operation NOTICE Solder or water splatter between plugs and circuit board can cause improper operation of control module Place a shield over the boiler internal controls and components during installation Failure to comply could result in severe personal injury death or substantial property damage Control indicator lights lockout modes See Charts 1 through 7 in this section for detailed troubleshooting procedures To reset control after a lockout turn off power at the 120 VAC service switch or turn down all thermostats Wait 45 seconds Then restore power or call for heat POWER light flashing alone Usually indicates reversed polarity of 120 VAC power wires POWER and TSTAT CIRC lights flashing Usually indicates stray voltage on external thermostat circuit wires usually due to miswired 3 wire zone valve POWER and PRESS SWITCH lights flashing Usually indicates pressure switch is closed when it should not be or pressure switch failed to close within 5 minutes of inducer starting POWER and FLAME lights flashing Usually indicates false flame sense or flame sensed when it shouldn t be there Part number 550 1
89. ting about the boiler Please have the boiler model number from the boiler rating label and the CP number from the boiler jacket You may list the CP number in the space provided on the Installation and service certificate found on page 30 or substantial property damage When servicing boiler To avoid electric shock disconnect electrical supply before performing maintenance To avoid severe burns allow boiler to cool before performing maintenance Boiler operation Do not block flow of combustion or ventilation air to boiler Should overheating occur or gas supply fail to shut off do not turn off or disconnect electrical supply to circulator Instead shut off the gas supply at a location external to the appliance Do not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control that has been under water Boiler water Do not use petroleum based cleaning or sealing compounds in boiler system Water seal deterioration will occur causing leakage between sections 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 Part number 550 110 260 0200 Failure to adhere to the guidelines on this page can result in severe personal injury death Co
90. ting the water temperature provided to the system and could result in excessive water temperature in the radiant tubing System bypass piping as shown in Figure 12 can be used with either zone valve or circulator zoning When used with circulator zoning however the boiler circulator item 3 must be piped as shown It cannot be used as one of the zoning circulators Do not apply system bypass piping if the reduced flow in the system could cause poor heat distribution That is system bypass piping reduces the flow in the system and increases the water temperature supplied to the system This can cause increased heat from radiators at the beginning of the system and reduced heat from radiators near the end of the system Koch Start with valve 7a fully closed and 7b fully open 2 Gradually open valve 7a while closing valve 7b until the temperature at gauge 8 reads at least 130 F at all times 3 Valve 7a regulates the amount of boiler supply water mixed with return water Valve 7b causes a pressure drop in the system needed to balance flow through valve 7a and the system 4 The valve adjustment should be done with the system at the coldest expected temperature 60 F for converted gravity systems or high mass radiant systems Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners resulting in severe personal injury death or substantial property damage Radiant heating
91. tion 9b page 32 for wiring A low water cutoff device is required when boiler is installed above radiation level or by certain state or local codes or insurance companies Use low water cutoff designed for water installations Electrode probe type is recommended Purchase and install in tee in supply piping above boiler Use backflow check valve in cold water supply as required by local codes Pressure temperature gauge Install pressure temperature gauge in tee on supply piping as shown in drawing on page 3 The gauge well is a self closing valve allowing removal of the gauge without draining the system Slowly remove pressure temperature gauge from well The self closing valve could leak if clogged with sediment If water begins to spray stop removing gauge Close system fill valve and drain enough water to release system pressure before continuing with gauge removal Escaping hot water could cause severe personal injury Relief valve Install relief valve vertically in 34 tapping on side of boiler See Figure 4 or 5 and the tag attached to the relief valve for manufacturer s instructions To avoid water damage or scalding due to relief valve operation Discharge line must be connected to relief valve outlet and run to a safe place of disposal Terminate the discharge line to eliminate possibility of severe burns should the valve discharge Discharge line must be as short as possible and be the
92. tion and part number of replacement part Results from using modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation Weil McLain part numbers are found in Weil McLain Boilers and Controls Repair Parts Lists The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on page 60 of this manual Failure to comply could result in severe personal injury Part number 550 110 260 0200 12b Boiler Manual al Replacement parts section assembly Figure 26 Section assembly Item number Description d _ Weil McLain part number 1 End section left hand 51124 311 103 830 2 End section right hand 51128 311 103 821 3 Intermediate section 51125 SES WG WEE eet not shown Replacement section assembly CGs 3 321 114 345 CGs 4 321 114 346 CGs 5 321 114 347 ei AEN CGs 6 __ 321 194 348 not shown Section replacement kit includes seals and sealant for 1 joint 381 354 527 d 4 Tie rod 7 6 without nut 3 per boiler CGs 3 560 234 500 CGs 4 560 234 501 CGs 5 560 234 502 A et CGs 6 dw 560 234 503 Bei g 5 J Nut he 2 per tie rod EN 561 928 235 8 6 Washer 7 6 1 per tie rod 562 248 684 7 Radiation plate 1 per joint 460 003 700 8 Collector hood and transition assembly CGs 3 450 020 511 CGs 4 450 020 512 CGs 5 450 020 513 CGs 6 450 020 514 9 Hig
93. tions resulting in severe personal injury death or substantial property damage Part number 550 110 260 0200 17 GOLD CGs Gas Fired Water Boiler 3d Water piping low temp systems Primary secondary preferred bypass piping method Temperature gauges 18 Valve adjustment Figure 12 and 13 only Primary secondary bypass piping is preferred because the flow rate and temperature drop in the heating circuit s is determined only by the heating circuit circulator s So adjustment of the bypass valves in the boiler circuit will not cause a change in the heating circuit rate and temperature distribution Figures 8 and 9 show suggested bypass arrangements using primary secondary bypass piping preferred for low temperature systems such as radiant heating systems or converted gravity systems For alternatives see pages 20 through 23 The bypass valves items 7a and 7b provide mixing of hot boiler outlet water with cooler system return water set to assure a minimum return water temperature at least 130 F to the boiler Set the valves as explained below Gauge 4a is suggested but optional on any system Gauge 4b is optional on converted gravity systems but required on radiant heating systems to display the water temperature being supplied to the radiant tubing Gauge 8 is required on all systems to assure the return water temperature is accurately set for a minimum of 130 F If this gauge is not
94. to Figure 27 page 54 for location Connect negative lead of MICROAMMETER to control sense pilot and gas valve terminal Figure 25 item 8 page 44 Connect positive lead of e Verify pilot ignition electrode 4 MICROAMMETER to sense wire electrode ceramic and spark e Verify pilot burner is securely e DISCONNECT red wire connected to terminal B see Table lead wire from control are in attached to pilot bracket bracket is G page 33 of the gas valve good condition Spark gap securely attached to cross tie and e Turn on power to boiler and allow to cycle As soon as pilot is should be approximately 1 8 there is no corrosion on the parts burning the MICROAMMETER should read at least 1 0 e Correct any above problems which would affect the ground path microamp replacing pilot if burner or for flame sense Is flame signal at least 1 0 microamp wiring is damaged e Verify that pilot flame rod flame rod No Yes e Reinstall air box top to operate ceramic and lead wire from control 4 boiler for retest after any module to flame rod are in good changes or corrections condition e f none of the previous steps e ifthewirina tomite e If none of the above corrects e Correct any above problems including replacing pilot o trol die to gas problem then replace the replacing pilot if burner or wiring is corrects problem then replace valve is intact replace the control module reinstall air box damaged the control module reinstall air EE EE NC E top and
95. trol While burners are operating move indicator on limit control below actual boiler water temperature Burners should go off while circulator continues to operate Raise setting on limit control above boiler water temperature and burners should reignite Test additional field installed controls If boiler has a low water cutoff additional high limit or other controls test for operation as outlined by manufacturer Burners should be operating and should go off when controls are tested When controls are restored burners should reignite Test ignition system safety device a Connect manometer to outlet side of gas valve b Start boiler allowing for normal start up cycle to occur and main burners to ignite c With main burners on manually shut off gas supply at manual main shutoff gas valve Burners should go off d Open manual main shutoff gas valve Manometer should confirm there is no gas flow LU UU wo Check out procedure checklist e Pilot will relight flame sensing element will sense pilot flame and main burners will reignite Set limit control s to system temperature requirements Adjust balancing valves and controls to provide design temperature to system For multiple zones adjust flow so it is about the same in each zone Verify thermostat heat anticipator if available set properly Refer to Field wiring manual section 6a Thermostat s Cycle boiler with thermostat Raise t
96. ual a Operation sequence 1 Read Lighting instructions on page 34 This information is also located on a label on the inside of the boiler jacket door panel 2 Raise room thermostat to call for heat Inducer and circulator energize After pressure switch proves proper airflow control module initiates 30 second prepurge 4 Control module sparks the pilot and opens pilot valve in main gas valve a If pilot does not light within 15 seconds pilot valve is closed and spark generator is turned off Control module initiates a 15 second postpurge then starts a new cycle b If pilot does light and control module senses flame current spark generator is turned off and main valve opens 5 During main burner operation 10 11 a Control module monitors pilot flame current If signal is lost main valve closes spark generator activates and sequence returns to step 4 b If power is interrupted control system shuts off pilot and main gas valves and restarts at step 1 when power is restored In the event the limit control shuts down the boiler The control module closes the pilot and main gas valves but keeps the inducer operating for 15 second postpurge The circulator continues to operate Lower room thermostat setting to stop call for heat Thermostat is satisfied Pilot and main gas valves are closed Inducer operates for 15 second postpurge Circulator is shut off Boiler
97. ure against all four sides of the base If insulation is damaged or displaced do not operate the boiler Replace or reposition insulation as necessary Failure to replace damaged insulation can result in a fire hazard causing severe personal injury death or substantial property damage Condensate drain system 1 Inspect condensate drain fittings and tubing Verify that condensate can flow freely to drain Oiled bearing circulators 1 The circulator shipped with the CGs boiler is water lubricated No oiling is required 2 Check other circulators in the system Oil any circulators requiring oil following circulator manufacturer s instructions Over oiling will damage the circulator 37 10b GOLD CGs Gas Fired Water Boiler Service amp maint annual start up continued LI Start up 38 1 Start the boiler following the instructions in manual section 7 2 Verify cold fill pressure is correct and that fill system is working properly 3 Verify antifreeze level if used is at the right concentration and that inhibitor level is correct 4 Check gas piping per manual Sections 5 and 7 verifying no indications of leakage and all piping and connections are in good condition 5 Read the Lighting instructions Figure 21 of this manual or on boiler label applying to the boiler 6 Start the boiler following the Lighting instructions and manual section 7 LJ Check test
98. urn water temperature at no less than 130 F regardless of system supply temperature Contact your Weil McLain representative for suggested piping and control methods Failure to prevent cold return water temperature to the boiler could cause corrosion damage to the sections or burners resulting in possible severe personal injury death or substantial property damage Part number 550 110 260 0200 Boiler Manual primary secondary preferred bypass piping for radiant heating or converted gravity systems Figure 8 Zoning with circulators e ZONE2 H a R ge eee e ZONE ae X Gi 1 i i 2 Ei 1 E ch P 12 46 o deif T 2 H Max m9 1 y Satoh ok He KH pet me 1 at ME Fe 7a SC A L E location y A 9 10 Cold 11 Wa 2 26014 E Li 1 Boiler isolation balancing valves 2 Flow check valve 3 System or zone circulator 4 System temperature gauges 5 Zone valve 6 Drain valve 7 System temperature valves see instructions to the left for adjusting valves 8 Blend temperature gauge 9 Relief valve Part number 550 110 260 0200 Figure 9 Zoning with zone valves ge ee ko ol ZONE 1 wm i z l Ki x 1 TIS ae Se hf Lod gt MAX F 3 Soe Se HH ot KY eae 13 Mg 7b 1 ae Fek Ja
99. ust be removed If they cannot be removed install combustion air piping to the boiler in accordance with the appropriate venting supplement Air openings 1 Verify that combustion and ventilation air openings to the boiler room and or building are open and unobstructed Check operation and wiring of automatic combustion air dampers if used Verify that boiler vent discharge and air intake are clean and free of obstructions Flue gas vent system and air piping 1 Visually inspect entire flue gas venting system and air piping if installed for blockage deterioration or leakage Repair any joints that show signs of leakage in accordance with vent manufacturer s instructions When air is ducted to boiler verify that air inlet hose is connected and properly sealed Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death Pilot and main burner flames 1 Visually inspect pilot burner and main burner flames as directed under Start up section 7 of this manual Water piping 1 Check the boiler interior piping and all system piping for signs of leaks 2 Repair any leaks before proceeding personal injury The boiler contains ceramic fiber and fiberglass materials Use care when handling these materials per instructions on page 60 of this manual Failure to comply could result in severe Part number 550 110 260 0200
100. ycle 23 GOLD CGs Gas Fired Water Boiler Venting and combustion air Install vent piping and air piping DANGER if used per appropriate Venting Supplement included in boiler envelope assembly Refer to Venting Supplements and to manual section 1 regarding requirements for vent system combustion air openings combustion air quality CGs Boiler must be vented and supplied with combustion and ventilation air as described in Weil McLain CGs Venting Supplements packed in envelope assembly with boiler Failure to do so will cause severe personal injury or death Use direct vent sealed combustion if combustion air quality cannot be assured to be free of contaminants Refer to page 9 for a list of potential contaminants and locations likely to contain them Operating the boiler with contaminated air will damage the boiler sections and vent resulting in possible boiler failure or leakage of flue products causing severe personal injury death or substantial property damage Gas piping Connecting gas supply piping to boiler 1 Remove jacket front panel and refer to Figure 14 to pipe gas to boiler a Install drip leg at inlet of gas connection to boiler Where local utility requires drip leg to be extended to the floor use appropriate length of pipe between cap and tee b Install ground joint union for servicing when required c Install manual shutoff valve in gas supply piping outside boiler
101. ypass alternate piping for radiant heating or converted gravity systems Figure 10 Boiler bypass piping Zoning with circulators Alternative to primary secondary piping Figures 8 and 9 N O Z m N mS A L A EEN j XH FINA FETHU E a A D A T Ge o VC E wegder D N FO j Y 9 10 Cold 11 L water fill T 12 26016 E KI h Boiler isolation balancing valves Flow check valve System or zone circulator System temperature gauges Zone valve Drain valve vn O A Q DN System temperature valves see instructions to the left for adjusting valves Blend temperature gauge Relief valve Part number 550 110 260 0200 Figure 11 Boiler bypass piping Zoning with zone valves Alternative to primary secondary piping Figures 8 and 9 3 BO eege Lo a ZONEI lt y x R1 1X Xi lt b 4b S40 AC i ef tH HEHE d 6 XI Alternate ca Ni 6 13 Gi ovation ak 7a HO 8 7b Y a T10 4aO Cold 11 8 12 a 26017 10 Automatic air vent with diaphrag

Weil-McLain 550-110-260/02002 Boiler User Manual

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