Weil-McLain GOLD CGt SERIES Operating instructions

GOLD CGt
TM
Natural gas-fired water boiler
with tankless heater
User’s
Information
Manual
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.
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
technician or the gas supplier.
Part Number 550-110-291/0709
GOLD CGt Gas-Fired Water Boiler User’s Information Manual
Please read this page first
How to use this
manual . . .
Hazard definitions
Boiler service and
maintenance
2
To . . .
Read/use . . .
Pages . . .
Learn
precautions
Warnings and definitions
Prevent air
contamination
Read list of air contaminants you must avoid. If
found, either remove products permanently
or isolate boiler and provide outside combustion air.
3
Identify boiler
components
The illustration on page 4, will show you the
location of the main components.
4
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 service technician before every heating season.
5
Start — or —
Shutdown
boiler
Use the Operating instruction sheet for the
gas valve installed on your boiler. Ask your service technician if you are unsure which one.
10
Troubleshoot
common
problems
Use the common problems/solutions table to
resolve typical heating system/boiler problems.
11
1, 2, and 3
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 damage.
Indicates special instructions on installation, operation or maintenance that
are important but not related to personal injury or property damage.
The Boiler manual is for use only by a qualified heating installer/service
technician. Refer only to this User’s Information Manual for your reference.
Improper installation, adjustment, alteration, service or maintenance can
cause property damage, personal injury (exposure to hazardous materials)
or loss of life. Installation and service must be performed by a qualified
installer, service agency or the gas supplier (who must read and follow the
supplied instructions before installing, servicing, or removing this boiler.
The boiler contains materials that have been identified as carcinogenic, or
possibly carcinogenic, to humans).
Part Number 550-110-291/0709
GOLD CGt Gas-Fired Water Boiler User’s Information Manual
STOP!! — Read before proceeding
Failure to adhere to the guidelines on this page can result in severe personal injury, death or substantial property
damage.
Air contamination
• To prevent potential of severe personal injury or death, check for products or areas listed in table at right before installing boiler. If any of these contaminants are found:
• remove contaminants permanently. — OR —
• isolate boiler and provide outside combustion air. See national, provincial or
local codes for further information.
Products to avoid
Spray cans containing chloro/fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Service and maintenance
Calcium chloride used for thawing
Sodium chloride used for water softening
•
•
•
To avoid electric shock, disconnect electrical supply before performing
maintenance.
To avoid severe burns, allow boiler to cool before performing maintenance.
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 air to boiler. This boiler is
equipped with a control which will automatically shut down the boiler should
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 removed, have the boiler and system checked by a
qualified service technician.
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 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, 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 between 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.
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.
Part Number 550-110-291/0709
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes
dryers
Chlorine-type bleaches, detergents, and
cleaning solvents found in household
laundry rooms
Adhesives used to fasten building products
and other similar products
Areas likely to have
contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
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GOLD CGt Gas-Fired Water Boiler User’s Information Manual
Boiler components
CGt
1
2
3
4
5
6
7
Control module
Transformer
Inducer
Air pressure switch
High limit
Boiler circulator
Tankless heater low limit
control
8 3-Way valve
9 Tankless heater
10 Wires to ambient temperature
switch
11 Relay
a
b
c
d
e
f
g
h
i
supply to system
return from system
stainless steel burners
flue outlet
gas valve
pressure/temperature gauge
relief valve
air vent connection
flame rollout thermal fuse
element (TFE)
j burner holding bracket
k pilot burner and bracket
l gas manifold
m cast iron boiler sections
n flue collector
o junction box
p drain valve
q burner shield
r tee 1 x 1 x 1/2 NPT
4
Part Number 550-110-291/0709
GOLD CGt Gas-Fired Water Boiler User’s Information Manual
Maintain boiler using schedule below
Service technician
(covered in Boiler Manual — for use only by a
qualified service technician)
Owner maintenance
(see following pages for instructions)
Inspect:
• Reported problems
• Check boiler area
Daily
• Check boiler pressure/
temperature gauge
• Boiler area
• Air openings
• Check boiler interior piping
• Flue gas vent system
• Check venting system
• Pilot and main burner flames
• Water piping
Monthly
ANNNUAL START-UP
• Check automatic air vents (if
used)
• Burners, base and inlet air box
• Oiled-bearing circulators
• Check air vents
• Check boiler relief valve
• Boiler heating surfaces
Service:
• Check air openings
Periodically
• Test low water cutoff (if used)
Every 6 months
• Operate relief valve
End of season
• Shut down procedure
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
Tankless water heater
If boiler is used to supply domestic hot water, limit
control should be set to supply adequate hot water.
Weil-McLain tankless heaters are rated at 200°F boiler
water temperature. To get rated output, set low limit
at 200°F. Limit can be adjusted to meet system hot
Part Number 550-110-291/0709
water requirements. Lowering the setting will cause a
slight variation in water temperature but will decrease
burner on-off cycling. High limit should be set at least
20° above low limit.
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GOLD CGt Gas-Fired Water Boiler User’s Information Manual
User maintenance procedures
Boiler must be serviced & maintained
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 on page 6 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, 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 6.
In addition to this maintenance,
the boiler must be serviced and
started up at the beginning of each
heating season by a qualified service
technician.
Component information
Rollout thermal fuse element
Cuts off gas flow should flame rollout occur. See Figure 1.
Figure 1 Rollout thermal fuse element
Do not attempt to place boiler in operation if rollout
thermal fuse element cuts off gas flow. Immediately
call a service technician. Failure to do so can cause
severe personal injury, death or substantial property
damage.
❏ Check daily . . . . . . . . . . . . . . . . . . .
Boiler area
6
To prevent potential of severe personal injury, death or
substantial property damage, eliminate all materials as
discussed below from the boiler vicinity. If found:
• Remove products immediately from the area.
If they have been there for an extended period, call
a qualified service technician to inspect the boiler
and vent system for possible damage from acid
corrosion.
• If products cannot be removed, immediately
call a qualified service technician to install an outside
combustion air source for the boiler (if not already
installed).
1. Combustible/flammable materials — Do not
store combustible materials, gasoline or any other
flammable vapors or liquids near the boiler. Remove
immediately if found.
2. Air contaminants — See listing of contaminants on
page 3.
Pressure/temperature gauge
1. Make sure the pressure reading on the boiler pressure/temperature gauge does not exceed 24 psig.
Higher pressure may indicate a problem with the
expansion tank or gauge.
2. Contact a qualified service technician if problem
persists.
Air openings
Verify that combustion and ventilation air openings
to the boiler room and/or building are open and unobstructed.
Part Number 550-110-291/0709
GOLD CGt Gas-Fired Water Boiler User’s Information Manual
❏ Check monthly . . . . . . . . . . . . . . . .
Boiler piping
Visually inspect for leaks around piping, circulators,
relief valve and other fittings. Immediately call a qualified service technician to repair any leaks.
Have leaks fixed at once by a qualified service technician.
Continual fresh makeup water will reduce boiler
life. Minerals can build up in sections, reducing heat
transfer, overheating cast iron, and causing section
failure.
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Severe damage to boiler
and system components can occur, resulting in possible
severe personal injury, death or substantial property
damage.
Venting system
Failure to inspect the vent system as noted above and
have them repaired by a qualified service technician can
result in vent system failure, causing severe personal
injury or death.
Check condensate drain
system
1. Inspect condensate drain fittings and tubing. Verify
that condensate can flow freely to drain.
Automatic air vents (if used)
1. See Figure 3.
2. Remove the cap from any automatic air vent in the
system and check operation by depressing valve 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.
Figure 3 Automatic air vent
1. Visually inspect all parts or the flue gas venting
system for any signs of blockage, leakage or joints
or deterioration of the piping.
2. Notify your qualified service technician at once if
you find any problem.
Boiler relief valve
1. Inspect the boiler relief valve (see Figure 2) 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 contact your qualified service
technician to inspect the boiler and system.
Figure 2 Relief valve
Part Number 550-110-291/0709
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GOLD CGt Gas-Fired Water Boiler User’s Information Manual
❏ Check monthly
Pilot burner flame
continued.
.........
Figure 4 Pilot burner and flame, typical
Proper pilot flame (see Figure 4):
1. Blue flame.
2. Inner cone engulfing pilot flame sensor.
3. Pilot flame sensor glowing cherry red.
Improper pilot flame:
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
Figure 5 Main burner flame, typical
Proper main burner flame (see Figure 5):
1. Yellow-orange streaks may appear (caused by
dust).
Improper main burner flame:
1. Overfired — Large flames.
2. Underfired — Small flames.
3. Lack of primary air — Yellow tipping on flames
(sooting will occur).
❏ Service periodically . . . . . . . . . .
Test low water cutoff (if installed)
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.
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Part Number 550-110-291/0709
GOLD CGt Gas-Fired Water Boiler User’s Information Manual
❏ Service every 6 months . . . . . . .
Operate boiler relief valve
To avoid water damage or scalding due to valve
operation, a metal discharge line must be connected to
relief valve outlet and run to a safe place of disposal. This
discharge line must be installed by a qualified heating
installer or service technician in accordance with the
instructions in the Boiler Manual. The discharge line
must be terminated so as to eliminate possibility of
severe burns should the valve discharge.
1. Before proceeding, verify that the relief valve outlet
has been piped to a safe place of discharge, avoiding
any possibility of scalding from hot water.
2. Read the boiler pressure/temperature gauge to make
sure the system is pressurized.
3. Lift the relief valve top lever slightly, allowing water
to relieve through the valve and discharge piping.
4. If water flows freely, release the lever and allow
the valve to seat. Watch the end of the relief valve
discharge pipe to ensure that the valve does not
weep after the line has had time to drain. If the valve
weeps, lift the seat again to attempt to clean the
valve seat. If the valve continues to weep afterwards,
contact your qualified service technician to inspect
the valve and system.
5. If water does not flow from the valve when you lift
the lever completely, the valve or discharge line
may be blocked. Immediately shutdown the boiler,
following the instructions on the inside jacket top
Lighting Instructions. Call your qualified service
technician to inspect the boiler and system.
❏ End-of-season shutdown . . . . . .
Follow boiler shutdown procedure
1. Follow “TO TURN OFF GAS TO APPLIANCE” on the
Operating instructions on the inside of the jacket
panel. You will also find these instructions on page
10 of this manual.
Use the Operating instruction for the gas valve
model installed on the boiler.
Part Number 550-110-291/0709
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.
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GOLD CGt Gas-Fired Water Boiler User’s Information Manual
Operating instructions
• Gas valve — Honeywell VR8204 and White-Rodgers 36E
FOR YOUR SAFETY READ BEFORE OPERATING
If you do not follow these instructions exactly, a fire or explosion may result
causing property damage, personal injury or loss of life.
A. 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.
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.
B. Before OPERATING , smell all around the
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.
D. 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.
What to do if you smell gas
• Do not try to light any appliance.
• 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.
• If you cannot reach your gas supplier, call the fire depart-
OPERATING INSTRUCTIONS
1. Stop! Read the safety information above on this label.
2. Set the thermostat to lowest setting.
3. Turn off all electrical power to the appliance.
4. Remove jacket front panel.
5. This appliance is equipped with an ignition device which automatically lights the burner.
Do not try to light the burner by hand.
6. Turn Gas control knob clockwise
to OFF.
7. 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.
8. Turn Gas control knob counterclockwise
to ON.
9. Turn on all electric power to the appliance.
10.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.
TO TURN OFF GAS TO THE APPLIANCE
1. Set the thermostat to lowest setting.
3. Remove jacket front panel.
2. Turn off all electric power to the appliance if service is to
be performed.
4. Turn Gas control knob clockwise
force.
to OFF. Do not
5. Replace jacket front panel.
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Part Number 550-110-291/0709
GOLD CGt Gas-Fired Water Boiler User’s Information Manual
Common problems and solutions
Symptom
Common Causes
Possible Corrections
Rapid cycling — boiler
turns on and off
frequently
Thermostat installed where drafts
or heat affect reading
Heat anticipator in thermostat
adjusted incorrectly
Incorrect limit setting
Locate thermostat on inner wall away from heat sources or cool
drafts.
Adjust thermostat per manufacturer's instructions.
Set limit according to system needs. Maximum setting is 220˚F.
Increase limit setting to decrease cycling.
Insufficient water flow through
Check all valves to and from boiler. Return to proper setting.
boiler
Confirm circulator size.
Frequent release of
Expansion tank sized too small
Call qualified service technician to check expansion tank
water through relief
operation and size.
valve
Flooded expansion tank
Call qualified service technician to check expansion tank
operation.
Inoperative limit control
Call qualified service technician to replace limit control.
Need to frequently add
Leaks in boiler or piping
Have qualified service technician repair leaks at once to avoid
makeup water
constant use of makeup water. Makeup water can cause mineral
deposits which, in turn, can cause boiler section failure. Do not
use petroleum-base stop-leak compounds.
Black water condition
Oxygen corrosion due to leaks in
Have qualified service technician repair at once. Keep pH of
boiler and piping
water between 7.0 to 8.5.
Popping or percolating
Mineral deposits in sections due to Call qualified service technician to de-lime boiler, if necessary. In
noise heard in boiler
constant use of makeup water
some cases, deposits will be too heavy to remove with de-liming
procedures.
Have qualified service technician repair leaks to eliminate need
for constant makeup water.
Incorrect pH of boiler water
Call qualified service technician to check pH level and correct.
pH should be maintained between 7.0 to 8.5.
Insufficient water flow through
Check all valves to and from boiler. Return to proper setting.
boiler
Confirm circulator size.
Metal flakes found in
Contaminated combustion air
Remove any contaminating products. See page 3 in this manual.
vent outlet or vent —
supply — See page 3 in this
Provide outside air for combustion. Kit available through Weilflueway corrosion
manual.
McLain distributor. Have qualified service technician pipe-up kit.
Condensation of combustion
Have qualified service technician inspect system piping and
gases in boiler sections
controls to verify proper regulation of return water temperature.
Some radiators or
Air in system
Bleed air from system through air vents in radiators or
baseboard units do not
baseboard units.
heat or are noisy
Low system pressure
Fill to correct pressure.
Check for leaks in boiler or piping. Have qualified service
technician repair at once.
High limit set too low
Adjust high limit to higher setting.
Domestic water from
Mineral deposits insulate internal
Have qualified service technician delime or replace coil.
tankless heater is hot
waterways of heater.
then suddenly turn cold. Boiler stop-leak compound has
Have qualified service technician remove and clean coil AND
been added to boiler water and is drain and flush boiler to remove stop-leak.
OR
insulating outside of coil.
Incorrect mixing valve setting for
Have qualified service technician adjust mixing valve setting.
Domestic water from
tankless heater.
tankless heater is
Domestic flow rate too high.
Have qualified service technician install flow check valve set to
always lukewarm.
rating of tankless heater.
Incorrect setting on tankless
Have qualified service technician raise tankless control setting.
heater control.
Adjust differential on tankless control to lower setting.
3-Way valve does not work.
Have qualified service technician inspect the 3-way valve wiring,
actuator and body. Check operation of valve. If actuator does not
move when the boiler is shut off and there is a call for domestic
water replace valve and actuator.
Part Number 550-110-291/0709
11
Weil-McLain
500 Blaine Street
Michigan City, IN 46360-2388
http://www.weil-mclain.com
12
Part No. 550-110-291/0709