GOLD CGs Gas-Fired Water Boilers Boiler Manual • Installation • Maintenance • Startup • Parts 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.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual How it works . . . ① ② ③ ④ ⑤ ⑥ 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.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual GOLD CGs Gas-Fired Induced-Draft Water Boiler Part number 550-110-260/0107
GOLD CGs Gas-Fired Water Boiler — Boiler Manual Contents 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........
GOLD CGs Gas-Fired Water Boiler — Boiler Manual Please read before proceeding Installer User Read all instructions before installing. 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.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 1a Prepare boiler location — codes & checklist Installations must follow these codes: • • • • • Local, state, provincial, and national codes, laws, regulations and ordinances. National Fuel Gas Code, ANSI Z223.1–latest edition. Standard for Controls and Safety Devices 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.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 1b Prepare boiler location — clearances Recommended SERVICE clearances Figure 2 Required MINIMUM clearances (Fig. 1) 1. Provide clearances for cleaning and servicing the boiler and for access to controls and components. See Figure 1 for recommendations. 2. Provide at least screwdriver clearance to jacket front panel screws for removal of front panel for inspection and minor service.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 1c Prepare boiler location — vent system Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death. Inspect existing chimney before installing boiler. Failure to clean or replace perforated pipe or tile lining will cause severe personal injury or death. DO NOT COMMON VENT — Do not install the CGs into a common vent with any other appliance.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 1d Prepare boiler location — contamination Please review the following information on potential combustion air contamination problems. Refer to Table 1 for products and areas which may cause contaminated combustion air. To prevent potential of severe personal injury or death, check for products or areas listed below before installing boiler.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 1e ✷ Prepare boiler location — air openings Combustion air opening location and sizing requirements depend on the clearances around the boiler. Check the boiler placement compared to Figure 1, page 7. If all clearances are at least equal to Figure 1, page 7, apply the sizing and placement of openings Louver allowance given on pages 10 and 11.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual Figure 3 Sizing air openings for CGs installations ✷ Part number 550-110-260/0107 11
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 2a Prepare boiler — placement & 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 location. 3. Remove crate. 4. Remove boiler from pallet. Do not drop boiler or bump jacket on floor or pallet. Damage to boiler can result. a. Tilt left side of boiler up and place a board under left legs. b.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 2b Prepare boiler — pressure test Hydrostatic pressure test Pressure test boiler before attaching water or gas piping (except as noted below) or electrical supply. Prepare boiler for test 1. Remove the shipping nipple (from CGs supply tapping) and remove the boiler relief valve. Temporarily plug the relief valve tapping with a ¾” NPT pipe plug. 2. Remove 1¼” nipple, reducing tee and drain valve from circulator hardware and pressure/temperature gauge carton.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 3a Water piping — general information General piping information Circulator 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 Section 9b, page 32 for wiring.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 3b Water piping — single-zone system Diaphragm-type or bladdertype expansion tank (Figure 4) Closed-type expansion tank 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. 1. Ensure expansion tank size will handle boiler and system water volume and temperature.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 3c Water piping — multiple zones Piping multiple zones Follow instructions on pages 14 and 15 to install nearboiler 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, page 17, to complete installation. Zoning with circulators (Figure 6) (return temp over 130°F) 1. Size each circulator to individual circuit requirements. 2.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 3c Water piping — multiple zones Figure 6 Zoning with circulators — return water 130°F or higher. 1 Boiler isolation (balancing) valves 2 Flow/check valve 3 System or zone circulator 5 Zone valve 6 Drain valve 9 Relief valve Figure 7 (continued) Zoning with zone valves — return water 130°F or higher. 10 Automatic air vent (with diaphragm-type expansion tank), or connect to tank fitting (closed-type expansion tank).
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 3d Piping — low temp systems Primary/secondary (preferred) bypass piping method 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.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 3d Piping — low temp systems Figure 8 Primary/secondary piping Zoning with circulators 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 instruc- tions to the left for adjusting valves) 8 Blend temperature gauge Part number 550-110-260/0107 Figure 9 (continued) Primary/secondary piping Zoning with zone valves 9 Relief valve 10
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 3d Piping — low temp systems BOILER-bypass piping method This piping method (Figures 10 and 11, page 21) 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.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 3d Piping — low temp systems Figure 10 Boiler-bypass piping Zoning with circulators Alternative to primary/secondary piping Figures 8 and 9) 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 550-110-260/0107 Figure 11 (continued)
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 3d Piping — low temp systems SYSTEM-bypass piping method This piping method (Figure 12, page 23) 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.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 3d Piping — low temp systems Figure 12 (continued) System-bypass piping Zoning with zone valve or circulators, return water 130°F or higher.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 4 Venting and combustion air Install vent piping and air piping (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.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 5 Gas piping Connecting gas supply piping to boiler Natural Gas: 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.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 6 Field wiring For your safety, turn off electrical power supply at Thermostat Failure to do so can cause severe personal injury or death. 1. Connect thermostat as shown on wiring diagram on boiler. 2. Install on inside wall away from influences of service entrance panel before making any electrical connections to avoid possible electric shock hazard. Wiring must be N.E.C. Class 1.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 7a 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.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 7a Start-up — preparation (continued) Inspect system water piping Inspect base insulation 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. Check to make sure insulation is secure against all four sides of the base. If insulation is damaged or displaced, do not operate boiler.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 7b Start-up — operate boiler 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. (continued) Figure 16 Typical pilot burner flame Check burner flames View pilot and main flames through the inspection port in the Air inlet box front cover.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 8 Check-out procedure — checklist ❏ Boiler and heat distribution units filled with water? ❏ Set limit control(s) to system temperature requirements. Adjust balancing valves and controls to provide design temperature to system. ❏ Automatic air vent, if used, open one full turn? ❏ Air purged from system? ❏ Air purged from gas piping? Piping checked for leaks? ❏ For multiple zones, adjust flow so it is about the same in each zone.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 9a Operation — sequence 1. Read appropriate Operating instructions in Section 9c. 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. 3. Circulator energizes. If limit circuit is closed, the inducer starts. After pressure switch proves proper airflow, control module initiates a 30-second prepurge. 4. Control module sparks the pilot and opens pilot valve in main gas valve. a.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 9b Operation — wiring diagrams Figure 19 Schematic wiring diagram 32 Part number 550-110-260/0107
GOLD CGs Gas-Fired Water Boiler — Boiler Manual Figure 20 Ladder wiring diagram Part number 550-110-260/0107 33
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 9c 34 Operating instructions CGs-3 to CGs-6 • Spark pilot • Natural or propane gas • Gas valve: Honeywell VR8204/VR8304 Part number 550-110-260/0107
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 9c Operating instructions CGs-3 to CGs-6 Part number 550-110-260/0107 • Spark pilot • Natural or propane gas • Gas valve: White-Rodgers 36E 35
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 9c 36 Operating instructions CGs-3 to CGi-6 • Spark pilot • Natural or propane gas • Gas valve: White-Rodgers 36C Part number 550-110-260/0107
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 10a Service and maintenance — schedule VERIFY PROPER OPERATION AFTER SERVICING Table 5 Service and maintenance schedules 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.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 10b Service & maintenance — annual start-up Air openings 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, page 37,and explained on the following pages must be performed to assure maximum boiler efficiency and reliability.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual ❏ Inspect . . . Burners, base and inlet air box The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on page 68 of this manual. Failure to comply could result in severe personal injury. If insulation is damaged or displaced, do not operate the boiler. Replace or reposition insulation as necessary.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 10b Service & maint. — annual start-up ❏ Check/test . . . 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.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 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 discharge line have not been altered or tampered with illegally. Certain naturally occurring conditions may corrode the valve or its components over time, rendering the valve inoperative.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 10b Service & 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.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 11a 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.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 11b Troubleshooting — air pressure switch Air pressure switch Make sure boiler water temperature is 100 °F or cooler before starting procedure to obtain appropriate readings. 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.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 11c Troubleshooting — control module Control module 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. Make sure ground wiring is installed per wiring diagram. Good grounding is extremely important for proper operation.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 11c Troubleshooting — control module (continued) Figure 25 Control module connections 46 Part number 550-110-260/0107
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 11d Troubleshooting — control module lights CHART 1 — Troubleshooting POWER light status — Usually indicates reversed 120 VAC polarity if POWER light flashes by itself — 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. Is POWER light off? No • Make sure service switch or circuit breaker is on or fuses are good.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 11d Troubleshooting — control module lights CHART 2 — TSTAT CIRC & POWER lights flashing — Usually indicates 48 VAC on thermostat circuit (stray voltage) — 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.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 11d Troubleshooting — control module lights (cont.) CHART 3 — PRESS SWITCH & POWER lights flashing — Usually indicates pressure switch stuck closed or failed to make within 5 minutes — Electrical shock hazard — Wherever you see sTURN OFF POWERs, follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 11d Troubleshooting — control module lights (cont.) CHART 4 — FLAME & POWER lights flashing — Usually indicates flame sensed when it shouldn't be there — 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.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 11d Troubleshooting — control module lights (cont.) CHART 5 — FLAME light flashing and POWER light on steady ALSO — Troubleshooting failure to establish main flame 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.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 11d Troubleshooting — control module lights (cont.) CHART 6 — PRESS SWITCH light flashing and POWER light on steady — 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 — Electrical shock hazard — Wherever you see �TURN OFF POWER�, follow the instructions.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 11d Troubleshooting — control module lights (cont.) 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. • Has it been at least 5 minutes since setting thermostat to call for heat? If not, wait 5 minutes.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 12a Replacement parts Section assembly............................................... 55 Base................................................................... 56 Jacket................................................................ 58 Trim ................................................................... 60 Controls.............................................................
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 12b Replacement parts — section assembly Figure 26 Section assembly Part number 550-110-260/0107 55
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 12c Replacement parts — base Figure 27 Base assembly 56 Part number 550-110-260/0107
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 12c Replacement parts — base Item (continued) Description Weil-McLain part number Base insulation kit (includes insulation for all base parts above plus gasket material needed between block assembly and base) CGs-3 CGs-4 CGs-5 CGs-6 381-356-515 381-356-516 381-356-517 381-356-518 Base assembly kit (includes base panels items 1, 2, 3, 4, 5, 6, 7, 8, 11,13, 22 and 23 plus insulation, Air box gaskets, and hardware) CGs-3 CGs-4 CGs-5 CGs-6 381-356-522 3
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 12d Replacement parts — jacket Figure 28 Jacket assembly 58 Part number 550-110-260/0107
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 12d Replacement parts — jacket 1 2 3 4 5 6 Junction box, 2x4 Panel, left side, with insulation Panel, right side, with insulation Panel, top front, with insulation Panel, top rear, with insulation Panel, door Natural Gas Propane Gas Boiler Model CGs-3 CGs-4 CGs-5 CGs-6 Boiler Model Weil-McLain part number (Available at local supply house) 381-355-701 381-355-708 381-355-715 381-355-722 381-355-729 381-355-732 381-355-735 381-355-738 381-35
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 12e Replacement parts — trim Figure 29 Trim assembly Item number 1 Description Pressure relief valve, ASME, 30 PSIG, ¾" male inlet Pressure relief valve, ASME, 30 PSIG, ¾" female inlet (Fittings shown are factory-installed on boiler.
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 12f Replacement parts — controls Figure 30 Gas control assembly Description Item number Manufacturer Manufacturer’s part number VR8204A2001 Weil-McLain part number Natural gas components 1 Gas valve, ½" x ½", CGs-3 through CGs-6 Honeywell 2 Pilot assembly kit with orifice and aluminum pilot gas tubing Weil-McLain 511-044-381 511-330-080 Propane gas components 1 Gas valve, ½" x ½", CGs-3 through CGs-6 Honeywell 2 Pilot assembly kit with o
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 13a Dimensions Figure 31 Dimensional drawing 62 Part number 550-110-260/0107
GOLD CGs Gas-Fired Water Boiler — Boiler Manual 13b Ratings DOE (Note 5) Table 7 Boiler ratings Boiler model number DOE Heating capacity (Btuh) (Note 1) (Note 2) CGs-3 0-2,000 feet Input (Btuh) Output (Btuh) 2,000-4,500 feet Input (Btuh) Output (Btuh) Net I=B=R ratings (Btuh) Boiler water content (gallons) (Note 3) DOE Seasonal efficiency (% AFUE) Vent size (Note 5) (Note 4) 57,000 67,000 57,300 60,300 51,600 50,000 1.5 85.
GOLD CGs Gas-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.
