Weil-McLain GOLD CGS 550-110-260/0107 Скачать руководство пользователя

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Part number 550-110-260/0107

GOLD CGs Gas-Fired Water Boiler — Boiler Manual

Troubleshooting — control module lights

(cont.)

11d

CHART 7

— Insufficient heat or no heat to system (

POWER

light on steady)

Electrical shock hazard — Wherever you see

TURN OFF POWER

, follow the instructions. Failure to follow

instructions could result in severe personal injury, death or substantial property damage.

• Replace rollout switch.

• Boiler is in standby.

• Set thermostat to call for

heat and recheck

operation.

• Verify

Sequence of

operation

Figure 18

page 31.

Replace control module.

Retest.

• Boiler water temperature exceeded

setting on limit switch with thermostat

calling for heat. Boiler is OK. (See normal

sequence of operation,

Figure 18

, p. 31.)

• Also check setting on limit switch (should

be above 140°F.).

• Has it been at least 5 minutes since setting thermostat to

call for heat? If not, wait 5 minutes. Is system heating?

• Is thermostat set to call for heat? Remove thermostat

wires at boiler and check continuity across the two wires.

If circuit isn't closed, check external thermostat (zone

valve, relay, etc.) wiring. Correct problems and retry.

• Reconnect external thermostat wiring at boiler.

Is thermostat circuit closed (continuity across wires)?

• If you have sufficient heat — boiler should be in normal

operating sequence. (See normal sequence of operation,

Figure 18

, page 31.)

• If you have less than sufficient heat —

Is vent or combustion air piping free of blockage?

Yes

• Correct conditions and

recheck operation.

• See

Figure 18

, page 31

for normal sequence of

operation.

Contact your Weil-McLain

sales representative.

• Replace control

module.

• Retest.

• Repair/replace

circulator. Retest.

• Repair/replace

wiring. Retest.

• Remove CIRCULATOR harness plug from

CIRCULATOR plug receptacle (

Figure 25, Item

, page 46

). Check with voltmeter across pins of

control module receptacle.

Does voltmeter show 120 VAC across pins?

Yes

Is boiler System circulator operating?

• Wait 5 minutes.

FLAME

light on?

Yes

• Wait for boiler water to cool to temperature 20 to 30 °F

lower than temperature set on limit switch.

Are limit switch contacts closed?

LIMIT

light on?

Yes

Are all red lights off?

Yes

Wait 30 seconds.

Are all red lights off?

Yes

• Replace control module.

• Retest.

• Check limit switch

contacts with continuity

checker.

Are limit switch contacts

closed?

Yes

• Replace

limit switch.

• Retest.

Yes

Check rollout switch

continuity — is switch

closed?

Yes

• Check any other

limit controls wired

into the limit

circuit. If all are

OK, then replace

control module.

• Retest.

If rollout thermal fuse element has

opened, determine cause and

correct condition. Failure to do so

will cause severe personal injury,

death or substantial property

damage.

Содержание GOLD CGS 550-110-260/0107

Страница 1: ...s 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 ...

Страница 2: ...cate the most likely reason for the problem see page 45 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 cont...

Страница 3: ...Part number 550 110 260 0107 GOLD CGs Gas Fired Water Boiler Boiler Manual GOLD CGs Gas Fired Induced Draft Water Boiler ...

Страница 4: ...jury 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 ...

Страница 5: ...ter 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 structu...

Страница 6: ... Gas supply piping Electrical power Check area around boiler Remove any combustible materials gasoline and other flammable liquids or other contaminants 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 or other contaminants Failure to keep boiler a...

Страница 7: ...ide proper air flow around the boiler The free area of each opening after deducting for louvers must be at least one square inch per 1 000 Btuh of boiler input If the building is of unusually tight construction see page 10 for definition the air openings must connect directly to outside or the building must have air openings to the outside as specified on page 10 If clearances are equal to or grea...

Страница 8: ... 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 Vent system The CGs boiler requires a special vent system designed for pressurized venting Model CGs 3 is rated ANSI Z21 13Category IV pressurizedvent likelytocondense in the vent Models CGs 4 5 and 6 are rated Z21 13 Category III pr...

Страница 9: ...the boiler air intake at all times you must inspect the boiler at least once weekly When inspecting clean the burners if necessary using the procedure given on page 39 Failure to follow these guidelines could result in severe personal injury death or substantial property damage Products to avoid Areas likely to have contaminants Spray cans containing chloro fluorocarbons Dry cleaning laundry areas...

Страница 10: ...o 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 same space Use Figure 3 pag...

Страница 11: ...Part number 550 110 260 0107 11 GOLD CGs Gas Fired Water Boiler Boiler Manual Figure 3 Sizing air openings for CGs installations ...

Страница 12: ... or substantial property dam age 3 Reinstall inlet air box top panel 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 7 16 open end wrench remove t...

Страница 13: ...ir during the fill Valve and nipple are not included with boiler Fill and pressure test 1 Open the shutoff valves you installed on supply and return connections 2 Slowly open boiler drain valve and fresh water sup ply to fill boiler with water 3 When water flows from shutoff valves close boiler drain valve 4 Close shutoff valves 5 Slowly reopen boiler drain valve until test pressure on the pressur...

Страница 14: ...ystems large volume systems originally designed for circulation by natural convection rather than a pump Chillers or air handling units 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 handl...

Страница 15: ...ure 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 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 throu...

Страница 16: ...so 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 sec tions or burners resulting in severe personal injury death or substantial property damage Radiant heating systems Preferably use primary secondary ...

Страница 17: ...k 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 page 15 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 3c Water piping multiple zones continued ...

Страница 18: ...ange in the heating circuit rate and temperature distribution Figures 8 and 9 page 19 show suggested bypass ar rangements 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 in Figures 8 and 9 items 7a and 7b provide mixing of hot boiler outlet water with ...

Страница 19: ...use an automatic air vent when using closed type expansion tank It would allow air to leave the system causing waterlog ging 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 page 15 13 Air separator and automatic vent if used Note that the fill valve must always ...

Страница 20: ...to the instructions following Figures 10 and 11 are alternative piping suggestions 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 page 23 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 ...

Страница 21: ...ansion tank It would allow air to leave the system causing wa terlogging 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 page 15 13 Air separator and automatic vent if used Note that the fill valve must always be connected to the expansiontank regardlessof locat...

Страница 22: ...eturn 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 rad...

Страница 23: ... of air separator to tank fitting as in Figure 5 page 15 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 page 21 Figure 13 Piping refrigeration systems Water piping refrigeration systems Prevent chilled water from entering Install boiler so that chilled medium is piped in parallel with the heati...

Страница 24: ...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 Install vent piping and air piping if used per appropri...

Страница 25: ...as 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 appropri ate 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 jacket when required by local codes or utility requirements d In Canada When using manual...

Страница 26: ... x 4 cover plate on the boiler junction box and mount the service switch remotely as required by the code 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...

Страница 27: ...fe Minerals can build up in sections reduc ing heat transfer overheating cast iron and causing section failure Verify water chemistry Consult local water treatment 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...

Страница 28: ...boiler life Minerals can build up in sections reducing heat transfer overheating cast iron and causing section failure 1 Check system piping for leaks If found shut down boiler and repair immediately 2 Vent air from system usingmanual vents Airinthesystemwillinterfere with circulation and cause heat distribution problems and noise 3 Inspect vent system thoroughly for signs of deterioration from co...

Страница 29: ...e 17 PROPER main burner flame characteristics 1 Yellow orange streaks may appear caused by dust IMPROPER main burner flame characteristics 1 Overfired Large flames 2 Underfired Small flames 3 Lack of primary air Yellow tipping on flames sooting will occur Start up if boiler doesn t start 7c 1 Loose connections blown fuse or service switch off 2 High limit switch set below boiler water tempera ture...

Страница 30: ...e 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 6 Thermostat s Cycle boiler with thermostat Raise to high...

Страница 31: ...trol module senses flame current spark generator is turned off and main valve opens 5 During main burner operation a Control module monitors pilot flame current If signal is lost main valve closes spark gen erator 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 6 In the event the lim...

Страница 32: ...Part number 550 110 260 0107 32 GOLD CGs Gas Fired Water Boiler Boiler Manual Operation wiring diagrams 9b Figure 19 Schematic wiring diagram ...

Страница 33: ...Part number 550 110 260 0107 33 GOLD CGs Gas Fired Water Boiler Boiler Manual Figure 20 Ladder wiring diagram ...

Страница 34: ...Part number 550 110 260 0107 34 GOLD CGs Gas Fired Water Boiler Boiler Manual 9c Operating instructions CGs 3 to CGs 6 Spark pilot Natural or propane gas Gas valve Honeywell VR8204 VR8304 ...

Страница 35: ...Part number 550 110 260 0107 35 GOLD CGs Gas Fired Water Boiler Boiler Manual Operating instructions CGs 3 to CGs 6 Spark pilot Natural or propane gas Gas valve White Rodgers 36E 9c ...

Страница 36: ...Part number 550 110 260 0107 36 GOLD CGs Gas Fired Water Boiler Boiler Manual 9c Operating instructions CGs 3 to CGi 6 Spark pilot Natural or propane gas Gas valve White Rodgers 36C ...

Страница 37: ...ntenance procedures given throughout this manual and in com ponent 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 VERIFY PROPER OPERATION AFTER SERVICING ...

Страница 38: ...ained per this manual 5 Reconnect vent to inducer outlet and replace all boiler components before returning to service 6 Check inside and around boiler for evidence of any leaks from the boiler If found locate source of leaks and repair The boiler should be inspected and started annu ally at the beginning of the heating season only by a qualified service technician In addition the maintenance and ...

Страница 39: ...uilding freeze damage Read and follow the WARNING on page 9 Failure to inspect and clear gas burner ports could result in severe personal injury death or substantial property damage 1 Inspect each burner to insure that every port is completely open 2 If any port is not completely clear run a vacuum at the burner inlet while cleaning the burner ports with a wire brush The vacuum will help to draw a...

Страница 40: ...ated 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 Make sure this type of tank is fitted with a tank fitting such as the B G Tank Trol or Taco Taco Trol This fitting reduces gravity circula tion of ai...

Страница 41: ...terways are clear Certain naturally occurring mineral deposits may adhere to the valve rendering it in operative 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 ...

Страница 42: ...ll be exposed to freezing temperatures If using antifreeze in system do not drain 2 Follow shutdown procedure 3 Remove venting system connection to boiler 4 Remove top jacket panel Turn back insulation 5 Remove collector box transition assembly Clean sealant from assembly and sections 6 Remove radiation plates hanging between sec tions 7 Remove burners from base Brush and vacuum burners to remove ...

Страница 43: ...y checker d U tube manometer 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 ...

Страница 44: ...re 24 Manometer connections Table 6 Pressure switch setpoint for elevations above 2 000 ft contact your local Weil McLain sales office for details Troubleshooting air pressure reading 1 If manometer reading is lower than the setpoint of the switch see Table 6 check for possible causes blockage in hoses obstruction in inducer housing outlet loose inducer wheel on motor shaft inducer motor not in pr...

Страница 45: ...ally 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 lig...

Страница 46: ...Part number 550 110 260 0107 46 GOLD CGs Gas Fired Water Boiler Boiler Manual Troubleshooting control module continued 11c Figure 25 Control module connections ...

Страница 47: ...Y plug Figure 25 item 2 page 46 on control module Using voltmeter check across top and bottom pins of PRIMARY receptacle Does voltmeter indicate 120 VAC No Yes Reinstall 120 VAC transformer PRIMARY plug Using voltmeter check across pins of receptacle Does voltmeter indicate 24 VAC No Yes Chart 2 Chart 6 TSTAT CIRC light flashing Chart 3 Chart 4 PRESS SWITCH light flashing Chart 5 FLAME light flash...

Страница 48: ...ermostat 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 z...

Страница 49: ...n 11b Replace if necessary Retest Try reseating plug in module receptacle and restart If inducer still does not work replace inducer assembly Retest No Yes Wait 45 seconds Does inducer motor operate No Yes Remove INDUCER plug Figure 25 Item 6 page 46 from plug receptacle of control module Place voltmeter leads across the 120 VAC N and 120 VAC H pins of the INDUCER receptacle left column center and...

Страница 50: ...45 seconds Turn on power to boiler Restart boiler following Operating instructions in this manual Section 9c Do FLAME and POWER lights still flash Boiler should now operate normally Original flashing FLAME light caused by gas valve not operating properly See normal sequence of operation Figure 18 page 31 Replace gas valve Retest boiler Are FLAME and POWER lights flashing No Yes No Yes Are manual m...

Страница 51: ...er at service switch or breaker Check flame signal Detach sense lead from igntion control Figure 25 item 8 page 46 Connect negative lead of MICROAMMETER to control sense terminal Figure 25 item 8 page 46 Connect positive lead of MICROAMMETER to sense wire DISCONNECT red wire connected to terminal B see Table G page 33 of the gas valve Turn on power to boiler and allow to cycle As soon as pilot is ...

Страница 52: ...er indicate the switch is closed Inspect and check wire harness from control module to pressure switch Reseat connector in control module receptacle If harness is intact and properly seated but problem persists replace control module Retest Check air pressure switch per manual Section 11 Replace if necessary Retest Replace inducer assembly Retest No Yes Remove INDUCER plug Figure 25 Item 6 page 46...

Страница 53: ...should be in normal operating sequence See normal sequence of operation Figure 18 page 31 If you have less than sufficient heat Is vent or combustion air piping free of blockage No Yes Correct conditions and recheck operation See Figure 18 page 31 for normal sequence of operation Contact your Weil McLain sales representative Replace control module Retest Repair replace circulator Retest Repair rep...

Страница 54: ... and include description 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 p...

Страница 55: ...Part number 550 110 260 0107 55 GOLD CGs Gas Fired Water Boiler Boiler Manual Replacement parts section assembly 12b Figure 26 Section assembly ...

Страница 56: ...Part number 550 110 260 0107 56 GOLD CGs Gas Fired Water Boiler Boiler Manual Replacement parts base 12c Figure 27 Base assembly ...

Страница 57: ...ase right side panel in Base assembly 7 Base back panel in Base assembly 8 Base front cross tie assembly in Base assembly 9 Pilot bracket 450 003 689 10 Pilot burner assembly Natural gas Pilot burner assembly Propane gas 511 330 080 511 330 081 11 Inlet air box front panel in Inlet air box front panel kit 12 Inlet air box front panel gasket Use Gasket kit 13 Inlet air box top panel in Inlet air bo...

Страница 58: ...Part number 550 110 260 0107 58 GOLD CGs Gas Fired Water Boiler Boiler Manual Replacement parts jacket 12d Figure 28 Jacket assembly ...

Страница 59: ...699 431 223 311 431 223 311 381 355 403 381 355 413 381 355 420 381 355 427 381 355 706 381 355 713 381 355 720 381 355 727 381 355 707 381 355 714 381 355 721 381 355 728 CGs 3 CGs 4 CGs 5 CGs 6 Boiler Model 7 8 9 10 11 12 Not shown Boiler Model Cross tie bottom front Panel interior with insulation Panel rear with insulation Air inlet fitting Inlet air hose Hose clamp 3 Gold touch up paint Weil M...

Страница 60: ...ameter short shank Fittings shown are shipped loose with boiler Weil McLain 380 000 000 3 Drain valve Fittings shown are included with boiler Conbraco Hammond Valve Matco Norca Watts 31 606 01 710 205F04 BD 2C 511 210 423 511 246 392 511 246 392 511 246 392 4 Circulator Fittings shown are shipped loose with boiler Bell Gossett Grundfos Taco NRF 22 103253 UP15 42FR TB4 007 511 405 118 511 405 126 5...

Страница 61: ... 3 through CGs 6 Honeywell VR8204M2701 511 044 354 2 Pilot assembly kit with orifice and aluminum pilot gas tubing Weil McLain 511 330 081 Natural gas and propane gas components 3 Control module United Technologies 1107 1 511 330 090 not shown Wiring harness Weil McLain 591 319 795 4 Air pressure switch 1 79 I W C CGs 3 1 48 I W C CGs 4 1 22 I W C CGs 5 0 95 I W C CGs 6 Tri Delta PPS10171 3013 PPS...

Страница 62: ...Part number 550 110 260 0107 62 GOLD CGs Gas Fired Water Boiler Boiler Manual Dimensions 13a Figure 31 Dimensional drawing ...

Страница 63: ...00 60 300 51 600 50 000 1 5 85 3 3 CGs 4 85 000 100 000 85 000 90 000 76 500 74 000 2 1 84 6 3 CGs 5 112 000 133 000 112 400 119 000 100 600 97 000 2 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 boiler 2 Based on standard test procedures prescribed by the United States Department of Energy 3 Net I B R ratings a...

Страница 64: ...n from the boiler and place it in a plastic bag for disposal Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid Eye Irrigate immediately 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 fibe...

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