Weil-McLain GOLD CGS 550-110-260/0107 User manual

Part No. 550-110-260/0107
This manual must only be used by a qualified heating installer/service technician. Before installing, read all
instructions, including this manual, the burner manual and any related supplements. Perform steps in the order
given. Failure to comply could result in severe personal injury, death or substantial property damage.
• Installation
• Startup
Boiler Manual • Maintenance
• Parts
GOLD CGs
Gas-Fired Water Boilers
DO NOT USE BOILER DURING CONSTRUCTION unless you provide dust-free air to the boiler area or
follow the requirements given on page 9. Failure to comply could result in severe personal injury, death or sub-
stantial property damage.

Part number 550-110-260/0107
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual
How it works . . .
①Control 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-second postpurge and waits for the next heat call.
The control module indicator lights show normal sequence when the lights are on steady.When
a problem occurs, the control module flashes combinations of lights to indicate the most likely
reason for the problem (see page 45).
②Transformer
The control transformer reduces line voltage to 24 volts for the gas valve and limit circuit.
③Inducer
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.
④Air pressure switch
The air pressure switch signals the control module, telling the control module whether air is
moving through the inducer.
⑤Water 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.)
⑥Boiler 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.
a supply to system
b return from system
c combustion air inlet
d flue outlet
e gas valve
f pressure/temperature gauge
g relief valve (not visible)
h air vent connection
i flame rollout switch
j air inlet box
k pilot burner and bracket
l stainless steel burners
m cast iron boiler sections
n flue collector
o junction box
Other boiler components:

Part number 550-110-260/0107 3
GOLD CGs Gas-Fired Water Boiler — Boiler Manual
GOLD CGs Gas-Fired Induced-Draft Water Boiler

Part number 550-110-260/0107
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GOLD CGs Gas-Fired Water Boiler — Boiler Manual
Contents
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of
various risk levels or to important information concerning the life of the product.
Indicates presence of hazards that will cause severe personal injury, death or substantial
property damage.
Indicates presence of hazards that can cause severe personal injury, death or substantial
property damage.
Indicates presence of hazards that will or can cause minor personal injury or property dam-
age.
Indicates special instructions on installation, operation or maintenance that are important but
not related to personal injury or property damage.
How it works ....................................................2–3
Hazard definitions ............................................... 4
Please read before proceeding ............................ 5
1 Prepare boiler location ...................................6–11
2 Prepare boiler...............................................12–13
3 Water piping .................................................14–23
4 Venting & combustion air................................... 24
5 Gas piping ......................................................... 25
6 Field wiring ....................................................... 26
7 Start-up ........................................................27–29
8 Check-out procedure......................................... 30
9 Operation .....................................................31–36
10 Service and maintenance .............................37–42
11 Troubleshooting............................................43–53
12 Replacement parts .......................................54–61
13 Dimensions and ratings ................................62–63

Part number 550-110-260/0107 5
GOLD CGs Gas-Fired Water Boiler — Boiler Manual
Please read before proceeding
Installer
Read all instructions before in-
stalling. Follow all instructions in
proper order to prevent personal
injury or death.
• Also refer to CGs Venting Supplements.
• 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.
User
• This manual is for use only by your qualified
heating installer/service technician.
• 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 writing 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.
The boiler contains ceramic fiber and fiberglass materials. Use care when handling these
materials per instructions on page 64 of this manual. Failure to comply could result in severe
personal injury.
Failure to adhere to the guidelines on this page can result in severe personal injury, death
or substantial property damage.
• Continual 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 im-
mediately 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.
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 techni-
cian 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 medi-
cines”. Serious damage to boiler, personnel and/or
property may result.