Weil-McLain GOLD CGs Leitfaden

GOLD CGs

Do not store or use gasoline or other flammable vapors and liquids in the

vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

•Do not try to light any appliance.

•Do not touch any electrical switch; do not use any phone in your

building.

•Immediately call your gas supplier from a neighbor’s phone. Follow

the gas supplier’s instructions.

•If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency

or the gas supplier.

If the information in this manual is not followed exactly, a fire or

explosion may result, causing property damage, personal injury or

loss of life.

Gas-Fired Water Boiler

User’s

Information

Manual

PartNo.550-110-261/0999

GOLD CGs — User’s Information Manual

2PartNo.550-110-261/0999

The following defined terms are used throughout this manual to bring attention to the pres-

ence of hazards of various risk levels or to important information concerning the life of the

product.

Hazard definitions

Please read this page first

Indicatespresenceofhazardsthatwill cause severepersonalinjury,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.

The User’s Information Manual provides information to the boiler owner/user for routine

operationand maintenance and emergencyshutdown. Detailed information onboiler instal-

lation,operation,start-up,serviceandpartsisincludedintheCGs Boiler Manual.TheCGs

Boiler Manual is intended only for use by a qualified service technician.

Boiler service and

maintenance

How to use this

manual . . .

To . . . Read/use . . . Pages . . .

Learn

precautions Warnings and definitions 1, 2, and 3

Prevent air

contamination

Laundry room or pool — make sure boiler air

is piped to boiler per manual.

Read list of air contaminants you must avoid.

Have boiler air piped in if you can’t avoid.

Maintain

boiler

Set up a plan for maintaining the boiler using

the schedule included in this manual.

Schedule an annual start-up by a qualified ser-

vice technician before every heating season.

5 –9

Locate boiler

components

How the boiler works

and illustration. 10 –11

Start —or —

Shutdown

boiler

Use the Lighting instruction sheet for the gas

valve installed on your boiler. Ask your service

technician if you are unsure which one. 12 or 13

Troubleshoot

common

problems

Use the common problems/solutions table to

resolve typical heating system/boiler problems. 14 –15

GOLD CGs —User’s Information Manual

3PartNo.550-110-261/0999

Failure to adhere to the guidelines on this page can result in se-

vere personal injury, death or substantial property damage.

Boiler service and maintenance —

• To avoid electric shock, disconnect electrical supply before per-

forming maintenance.

• Toavoidsevereburns,allow boiler to cool beforeperformingmain-

tenance.

• You must maintain the boiler as outlined in the manual and have the

boiler started up and serviced at least annually by a qualified

service technician to ensure boiler/system reliability.

Boiler operation —

•Do not block flow of combustion or ventilation airtoboiler.This

boiler is equipped with a control which will automatically shut down

the boiler should air or vent be blocked. If vent or air blockage is

easily accessible and removable, remove it. The boiler should attempt

to restart within an hour. If blockage is not obvious or cannot be re-

moved,have the boiler and system checked by a qualified service tech-

nician.

• Should overheating occur or gas supply fail to shut off, do not

turn off or disconnect electrical supply to pump. Instead, shut off

the gas supplyatalocationexternal to the appliance.

•Do not use this boiler if any part has been under water.Immedi-

ately call a qualified service technician to inspect the boiler and to

replace any part of the control system and any gas control, which has

been under water.

•Have the building monitored when it is vacant for an extended

period. Safety controls can shut down the boiler at any time. The loss

of heat can result in significant damage due to freezing.

Boiler water —

• DO NOT use petroleum-based cleaning or sealing compounds in

boiler system.Water seal deterioration will occur, causing leakage be-

tween sections and damage to heating system components. This can

result in substantial property damage.

• DO NOT use "homemade cures" or "boiler patent medicines".

Serious damage to boiler, personnel and/or property may result.

• Continualfreshmakeup water will reduce boiler life.Mineralbuild-

up in sections reduces heat transfer, overheats cast iron, and causes

section failure. Addition of oxygen and other gases can cause internal

corrosion. Leaks in boiler or piping must be repaired at once to pre-

vent makeup water.

•Do not add cold water to hot boiler.Thermalshockcancausesec-

tions to crack.

STOP!! —Read before proceeding

GOLD CGs —User’s Information Manual

4PartNo.550-110-261/0999

Air contamination

Common household and hobby products often con-

tain fluorine or chlorine compounds. When these

chemicalspassthroughtheboiler,theycanformstrong

acids in the vent system or boiler. The acid can eat

through the vent or boiler wall, causing serious dam-

If the boiler is installed in any area likely to cause contamination, or if products which

wouldcontaminatetheaircannotberemoved,youmustpipe combustion air to the boiler

air intake. Contaminated combustion air will damage the boiler and vent system, resulting in

possible severe personal injury, death or substantial property damage.

Do not operate a CGs boiler in a laundry room or pool facility, for example,without

using ducted outside air. These areas will always contain contaminants.

age and presenting a possible threat of flue gas spillage

into the building.

Please read the information below. If the contaminat-

ing chemicals will be present, have your installer pipe

the boiler air from outside per the Boiler Manual.

Prevent combustion air contamination

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

Hydrochloric acid/muriatic acid Furniture refinishing areas and establishments

Cements and glues New building construction

Antistatic fabric softeners used in clothesdryers 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

GOLD CGs —User’s Information Manual

5PartNo.550-110-261/0999

Maintain boiler using schedule below

Service technician

(covered in CGs Boiler Manual —

for use only by a qualified service technician)

Owner maintenance

(see following pages for instructions)

NNNUAL

START

Inspect:

• Reported problems

• Boiler area

• Air openings

• Flue gas vent system (and air piping)

• Pilot and main burner flames

• Water piping

• Boiler heating surfaces

• Burners, base and inlet air box

• Condensate drain system

Service:

• Inducer motor

• Oiled-bearing circulators

Start-up:

• Perform start-up per manual

Check/test:

• Gas piping

• Cold fill and operating pressures

• Air vents and air elimination

• Limit controls and cutoffs

• Expansion tank

• Boiler relief valve

Review:

• Review with owner

Daily

• 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 termination/air intake

screens

Every 6 months • Oil inducer motor

• Operate relief valve

End of season • Shut down procedure

GOLD CGs —User’s Information Manual

6PartNo.550-110-261/0999

User maintenance procedures

Check boiler areaCheck boiler area

Check boiler area

The boiler should be inspected and started annually, at the beginning of

the heating season, only by a qualified service technician. In addition, the

maintenanceandcareoftheboilerdesignatedonpage5andexplainedon

the following pages must be performed to assure maximum boiler effi-

ciency and reliability. Failure to service and maintain the boiler and sys-

tem could result in equipment failure, causing possible severe personal

injury, death or substantial property damage.

The following information provides detailed instructions for completing

the maintenance items listed in the maintenance schedule, page 5. In ad-

dition to this maintenance, the boiler must be serviced and started up at

the beginning of each heating season by a qualified service technician.

❏Check daily . . . . . . . . . . . .

❏Boiler must be serviced & maintained

this manual. If any of these products are in the

room from which the boiler takes its combustion

air, they must be removed immediately or the

boiler combustion air must be supplied from out-

side. See WARNING above.

Check air openingsCheck air openings

Check air openings

1. Verify that combustion and ventilation air open-

ings to the boiler room and/or building are open

and unobstructed.

2. Verify that boiler vent discharge and air intake are

clean and free of obstructions. Remove any debris

on the air intake or flue exhaust openings.

Check boiler pressure/Check boiler pressure/

Check boiler pressure/

temperature gaugetemperature gauge

temperature gauge

1. Make sure the pressure reading on the boiler pres-

sure/temperature gauge does not exceed 24 psig.

Higher pressure may indicate a problem with the

expansion tank.

Contact a qualified service technician if problem

persists.

To prevent potential of severe personal injury, death

orsubstantial property damage, eliminate all materials

discussed below from the boiler vicinity. If contami-

nants are found:

Remove products immediately from the area. If they

havebeenthereforanextendedperiod,callaqualified

service technician to inspect the boiler and vent sys-

tem for possible damage from acid corrosion.

If products cannot be removed, immediately call a

qualified service technician to install an outside com-

bustion air source for the boiler (if not already in-

stalled).

1. Combustible/flammable materials —Do not store

combustible materials, gasoline or any other flam-

mable vapors or liquids near the boiler. Remove

immediately if found.

2. Air contaminants —Products containing chlorine

or fluorine, if allowed to contaminate the boiler

intake air, will cause acidic condensate in the vent

and boiler. This will cause significant damage to

the vent and/or boiler if allowed to continue. Read

the list of potential materials listed on page 4 of

GOLD CGs —User’s Information Manual

7PartNo.550-110-261/0999

User maintenance procedures continued

Check boiler interior piping

1. Remove boiler jacket top.

2. Visually inspect for leaks around internal piping,

circulators, relief valve and other fittings. Immedi-

atelycallaqualifiedservicetechniciantorepairany

leaks.

Check venting system

1. Visually inspect the flue gas vent piping for any

signs of blockage, leakage or joints or deteriora-

tion of the piping. Notify your qualified service

technician at once if you find any problem.

❏Check monthly . . . . . . . . . . . .

Figure 2 —Automatic air vent

Figure 1 — Relief valve

Have leaks fixed at once by a qualifed service techni-

cian. Continual fresh makeup water will reduce boiler

life. Minerals can build up in sections, reducing heat

transfer,overheatingcastiron,andcausingsectionfail-

ure.

Do not use petroleum-based cleaning or sealing com-

pounds in boiler system. Severe damage to boiler and

system components can occur, resulting in possible

severe personal injury, death or substantial property

damage. Check automatic air vents (if

used)

1. SeeFigure 2.

2. Remove the cap from any automatic air vent in

thesystemandcheckoperationbydepressingvalve

B slightly with the tip of a screwdriver.

3. If the air vent valve appears to be working freely

and not leaking, replace cap A, twisting all the way

on.

4. Loosen cap A one turn to allow vent to operate.

5. Have vent replaced if it does not operate correctly.

Check boiler relief valve

1. Inspect the boiler relief valve (see Figure 1) and

the relief valve discharge pipe for signs of weeping

or leakage.

2. If the relief valve often weeps, the expansion tank

may not be working properly. Immediately con-

tactyour qualified service technician to inspect the

boiler and system.

Failure to inspect the vent system as noted above and

havethemrepairedby aqualifedservice techniciancan

result in vent system failure, causing severe personal

injury or death.

Check condensate drain system

1. Inspectcondensatedrainfittingsandtubing.Verify

that condensate can flow freely to drain.

GOLD CGs —User’s Information Manual

8PartNo.550-110-261/0999

User maintenance procedures

Operate boiler relief valve

1. Before proceeding, verify that the relief valve out-

lethasbeenpipedtoasafeplaceofdischarge,avoid-

ing any possibility of scalding from hot water.

To avoid water damage or scalding

due to valve operation, a metal dis-

charge line must be connected to

relief valve outlet and run to a safe

placeofdisposal.Thisdischargeline

must be installed by a qualifed

heating installer or service techni-

cianinaccordancewiththeinstruc-

tions in the Boiler manual. The

discharge line must be terminated

so as to eliminate possibility of se-

vere burns should the valve dis-

charge.

2. Read the boiler pressure/temperature gauge to

make sure the system is pressurized.

3. Lift the relief valve top lever slightly, allowing wa-

ter to relieve through the valve and discharge pip-

ing.

4. If water flows freely, release the lever and allow the

valve to seat.Watch the end of the relief valve dis-

Clean vent termination & air

intake screens

1. Remove all lint and debris from both the boiler air

intake screen and the flue discharge screen.

2. The boiler control module will sense blockage of

the air intake or flue and lockout if the blockage is

excessive. It will signal the failure by flashing the

appropriate indicator lights on the control board.

3. If removing the debris does not allow the boiler to

operate correctly afterwards, contact your qualifed

Oil inducer motor

1. Use only S.A.E.20 motor oil.DO NOT use house-

hold universal oils.

Use only S.A.E. 20 motor oil to lu-

bricate the inducer motor. Do not

use common universal household

oils.

2. Place a few drops of oil in each of the two oiler

cups on the inducer motor.

❏Service periodically . . . . . . . . . . . .

❏Service every 6 months . . . . . . . . .

service technician to inspect the boiler and vent/

air systems.

Test low water cutoff (if

installed)

1. If the system is equipped with a low water cutoff,

test the low water cutoff periodically during the

heating season, following the low water cutoff

manufacturer’s instructions.

charge pipe to ensure that the valve does not weep

after the line has had time to drain. If the valve

weeps,lifttheseatagaintoattempttocleanthevalve

seat.Ifthevalvecontinuestoweepafterwards,con-

tactyour qualified service technicianto inspect the

valve and system.

5. If water does not flow from the valve when you lift

thelevercompletely,thevalveordischargelinemay

be blocked. Immediately shutdown the boiler, fol-

lowing the instructions on the inside jacket top

Lighting Instructions. Call your qualified service

technician to inspect the boiler and system.

GOLD CGs —User’s Information Manual

9PartNo.550-110-261/0999

User maintenance procedures continued

Follow boiler shutdown procedure

1. Follow“TO TURN OFF GAS TO APPLIANCE”on the Lighting in-

structions on the inside of the jacket top panel. You will also find

theseinstructionsonpages 12and 13of this manual.Use theLighting

instruction for the gas valve model installed on the boiler.

2. Do not drain system unless exposure to freezing temperatures will

occur.

3. Do not drain the system if it is filled with an antifreeze solution.

4. Do not shut down boilers used for domestic water heating. They must

operate year-round.

❏End-of-season shutdown . . . . . . . .

GOLD CGs —User’s Information Manual

10 PartNo.550-110-261/0999

How the boiler 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

continueindefinitely until pilot flame isestablished 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.

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. NOTE —The

control module provides a pump exercising routine. If the boiler is not operated for 30 days,

the control module will power the circulator for 30 seconds, then off.

asupply to system

breturn from system

ccombustion air inlet

dflue outlet

egas valve

fpressure/temperature gauge

grelief valve (not visible)

hair vent connection

iflame rollout switch

jair inlet box

kpilot burner and bracket

lstainless steel burners

mcast iron boiler sections

nflue collector

ojunction box

Other boiler components:

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