Weil-McLain GOLD CGa Manual

Gas-fired water boilers

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Installation and maintenance manual (68 pages)

Installation and maintenance instructions manual (69 pages)

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GOLD CGa

Gas-Fired Water Boilers

Boiler Manual

This manual must only be used by a qualiﬁed heating installer/service technician.

, read all

Before installing

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.

Part No. 550-101-009/0107

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Page 1 ™ GOLD CGa ® Gas-Fired Water Boilers Boiler Manual This manual must only be used by a qualiﬁed heating installer/service technician. , read all Before installing instructions, including this manual, the burner manual and any related supplements. Perform steps in the order given.
Page 2: How Is Works
GOLD CGa Gas-Fired Water Boiler — Boiler Manual How it works . . . Control module The control module (used on ) responds to signals from the room thermostat and boiler limit circuit to operate the boiler circulator, pilot burner, gas valve and vent damper. When room thermostat calls for heat, the control module starts the system circulator and activates the vent damper (causing it to drive open).
Page 3 GOLD CGa Gas-Fired Water Boiler — Boiler Manual GOLD CGa Gas-Fired Water Boiler Part Number 550-101-009/0107...
Page 4: Table Of Contents
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Contents How is works ............ 2-3 Hazard deﬁnitions ..........4 Please read before proceeding ......5 Prepare boiler location ........6–11 Prepare boiler ..........12-15 Water pi ping ..........16-25 Gas pi ping ............26 Field wiring ............
Page 5: Please Read Before Proceeding
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Please read before proceeding Installer User . Follow all instructions in stalling proper order to prevent personal injury or death. your reference. when determining boiler location. must be ﬁled immediately against the transportation company by the consignee.
Page 6 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — codes & checklist Installations must follow these codes: ws, regulations and ordinances. des. other performance criteria when boiler underwent tests speciﬁed Before locating the boiler, check the following:...
Page 7: Prepare Boiler Location
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — clearances Required MINIMUM clearances if foundation is used. Fire can result, causing severe personal injury, death located on the wall or door or substantial property damage. opposite the boiler FRONT (see Figure 1b)
Page 8: Prepare Boiler
GOLD CGa Gas-Fired Water Boiler — Boiler Manual 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.
Page 9 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air contamination Please review the following information on potential Refer to for products and areas which may cause combustion air contamination problems. contaminated combustion air. To prevent potential of severe personal injury or death, check for products or areas listed below before installing boiler.
Page 10 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler location — air openings to Figure 1a, page 7. , apply the sizing and placement of openings given on pages 10 and 11. you must provide air openings sized and located as shown in Figure 1b, page 7.
Page 11 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Unusually tight construction of openings — the minimum areas FREE AREA given in this manual are free area (equals the area, buildings in which: length times width of opening, after deduction for a.
Page 12 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler — placement and setup Place boiler/crate near must be used. Failure to do so will position result in severe personal injury, death or substantial property dam- until installa- age. tion site is ready.
Page 13 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler — pressure test Hydrostatic pressure test 5. Slowly reopen boiler drain valve until test pressure Pressure test boiler attaching water or gas piping of not more than 45 psi is reached on the pressure/ or electrical supply (except as noted below).
Page 14 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler — draft hood & spill switch Draft hood installation Spill switch installation 1. Fasten spill switch to draft hood as shown in 1. Orient draft hood with spill switch mounting holes to front of boiler as shown in Figure 7.
Page 15 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Prepare boiler — vent damper installation These systems are used on gas-ﬁred boilers with vent Installation without vent damper installed. 1. Install vent damper horizontally or vertically as shown in vent damper manufacturer’s instructions.
Page 16: Water Pi Ping
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Water piping — general information General piping information Circulator The circulator is shipped loose (wiring pre-attached to ditional is needed. Install control in supply piping boiler) to allow you to locate it either in the return or between boiler and isolation valve.
Page 17 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Water piping — single-zone system Undersized expansion tanks cause system water to be lost from relief valve and makeup water to be added through ﬁll valve. Eventual section failure can result. Diaphragm-type or bladder-...
Page 18 . Instead, provide controls and piping which can regulate the boiler return water Weil-McLain representative for suggested piping and control methods. Failure to prevent cold return water temperature to the boiler could cause corrosion damage to the sections or burners, resulting in possible severe personal injury, death or substantial property dam- age.
Page 19 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Water piping — multiple zones (continued) For systems with possible low return-water temperature (such as converted gravity systems, radiant heating systems and heat pump systems), refer to the special piping suggestions of , as applies.
Page 20 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems the water temperature being supplied to the radiant Primary/secondary (preferred) tubing. Bypass piping method on all systems to assure the return bypass piping is preferred because water temperature is accurately set for a minimum of the flow rate and temperature drop in the heating 130°F.
Page 21 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) Automatic air vent (with diaphragm-type expansion tank), or connect to tank ﬁtting (closed-type expan- Flow/check valve sion tank). use an automatic air vent when DO NOT using closed-type expansion tank.
Page 22 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) BOILER-bypass piping to the boiler. (When setting the valves without gauge installed — using cold or room temperature water method — assume the return water temperature to be 60°F. Set the valves so gauge reads at least 120°F.
Page 23 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) Automatic air vent (with diaphragm-type expansion tank), or connect to tank ﬁtting (closed-type expan- Flow/check valve sion tank). use an automatic air vent when DO NOT using closed-type expansion tank.
Page 24 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) SYSTEM-bypass piping apply system-bypass piping if the reduced ﬂow in the system could cause poor heat distribution. method That is, system-bypass piping reduces the ﬂow in the...
Page 25 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Piping — low temperature systems (continued) Water piping — refrigeration systems Install boiler so that chilled medium is piped in parallel with the heating boiler. Use appropriate valves to prevent chilled medium from entering boiler. See Figure 18 for typical installation of balancing valve and check valve.
Page 26: Gas Piping
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Gas piping Connect gas supply piping to boiler Natural Gas: 1. Remove jacket front panel and refer to to pipe gas to boil- 1. Refer to on rated boiler input (divide by 1,000 to obtain cubic at inlet of gas connection to boiler.
Page 27: Field Wiring
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Field wiring For your safety, to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. If rollout thermal fuse element wire as supplied with boiler must be replaced, type wire or equivalent must be used.
Page 28: Start-Up
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Start-up — preparation Check for gas leaks Determine if water treatment is needed ing initial operation, smell near the in boiler system. Severe damage to boiler ﬂoor and around the boiler for gas will occur, resulting in substantial property damage.
Page 29 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Start-up — preparation (continued) Fill the system with water Inspect system water piping and boiler drain cock. After ﬁlling the boiler and system with water, throughout the system for leaks. If found, repair immediately.
Page 30 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler proceed with boiler operation unless boiler and system have been ﬁlled with water and all instruc- tions and procedures of previous manual sections have been completed. Failure to do so could result in severe personal injury, death or substantial property damage.
Page 31 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Start-up — operate boiler (continued) Start the boiler from to start the boiler. Remove boiler jacket door and note the gas valve manufacturer will reduce boiler life. Minerals and model number. Use only the lighting/operat-...
Page 32 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Start-up — verify operation or for operation and lighting/operating information. Check burner ﬂames Typical pilot burner ﬂame Pilot burner ﬂame ( PROPER pilot ﬂame 2. Inner cone engulﬁng thermocouple (standing pilot) or pilot ﬂame sensor (spark-ignited pilot).
Page 33: Check-Out Pr Ocedure
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Check-out procedure — checklist 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. page 12 to check size and fuel type.
Page 34: Operation - Standing Pilot Boilers
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operation — standing pilot boilers Follow all procedures given in this manual and light- ing instructions when operating the boiler. Failure to main ignited until thermostat circuit or limit circuit do so could result in severe personal injury, death or substantial property damage.
Page 35 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Lighting instructions CGa-25 to CGa-8 Part Number 550-101-009/0107...
Page 36 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Lighting instructions CGa-25 to CGa-8 Part Number 550-101-009/0107...
Page 37: Operation - Spark-Ignited Pilot Boilers
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operation — spark-ignited pilot boilers Follow all procedures given in this manual and operating instructions when operating the boiler. Failure to do so could result in severe personal injury, death or substantial current.
Page 38 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operation — spark-ignited pilot system (continued) Figure 25a Schematic wiring diagram — Spark-ignited pilot system Part Number 550-101-009/0107...
Page 39 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operation — spark-ignited pilot system (continued) Figure 25b Ladder wiring diagram — Spark-ignited pilot system Part Number 550-101-009/0107...
Page 40 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operating instructions CGa-25 to CGa-8 Part Number 550-101-009/0107...
Page 41 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operating instructions CGa-25 to CGa-6 Part Number 550-101-009/0107...
Page 42 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operating instructions CGa-25 to CGa-6 Part Number 550-101-009/0107...
Page 43 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Operating instructions CGa-7 to CGa-8 Part Number 550-101-009/0107...
Page 44: Service And Maintenance
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service and maintenance — schedule VERIFY PROPER OPERATION AFTER SERVICING Service and maintenance schedules (service technician and user) Service technician Owner maintenance (see following pages for instructions) (see CGa User’s Information Manual for instructions)
Page 45 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service & maintenance — annual start-up of the listed in this manual. If any of these are present in the boiler intake air vicinity, they must be removed. If they The boiler should be...
Page 46 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) Inspect . . . 2. Inspect burners and all other components in the boiler base. 3. If burners must be cleaned, raise rear of each...
Page 47 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) Check/test Expansion tank 1. Expansion tanks provide space for water to move in an out as the heating system water expands due to Gas piping temperature increase or contracts as the water cools.
Page 48 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) Check/test (continued) Safety relief valves should be Boiler relief valve , by a 1. Inspect the relief valve and lift the lever to verify licensed plumbing contractor or ﬂow as in the following warnings, excerpted from...
Page 49 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Service & maintenance – annual start-up (cont.) Cleaning boiler heating surfaces The boiler contains ceramic ﬁber and ﬁberglass materi- als. Use care when handling these materials per instruc- tions on of this manual. Failure to comply burner ports are free of debris.
Page 50 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — procedure (continued) Check the following: 1. Wire connectors to control module are securely plugged in at module and originating control. or propane gas pressure upstream of gas valve. b. With boiler on: gas valve.
Page 51: Troubleshooting: Standing Pilot Boilers
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — standing pilot boilers CHART 1 — Standing pilot — Boiler will not fire Is damper harness securely plugged in at both ends? Secure connections. Check for loose wire connections or bad relay on Is 24VAC present across transformer terminals C &...
Page 52 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers The information on this page and Control module splatter between plugs and circuit board Solder or water can cause improper operation of control module. Place a These boilers are equipped with an...
Page 53 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) Part Number 550-101-009/0107...
Page 54 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 2 — Spark-ignited pilot — 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.
Page 55 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 3 — Spark-ignited pilot — 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.
Page 56 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 4 — Spark-ignited pilot — DAMPER light flashing — If POWER light is flashing: Usually indicates vent damper failed to prove open within 5 minutes —...
Page 57 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 5 — Spark-ignited pilot — 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.
Page 58 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 6 — Spark-ignited pilot — 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.
Page 59 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Troubleshooting — spark-pilot boilers (continued) CHART 7 — Spark-ignited pilot — Insufficient heat or no heat (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.
Page 60: Replacement Parts
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Replacement parts Section assembly ..........61 Base ..............62 Jacket ............... 63 Trim ..............64 Controls ............65 Replacement parts must be purchased through a local Weil-McLain distributor. When ordering, specify boiler model and size and include description and part number of replacement part.
Page 61 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Replacement parts — section assembly Item Description Weil-McLain Item Description Weil-McLain number part number number part number End section, left hand, 51124 311-103-830 High limit, 30° Honeywell 510-312-250 differential, with well L4080D1036...
Page 62 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Replacement parts — base Base assembly, manifold, oriﬁces and burners Item Description Weil-McLain number part number Base assembly kit CGa-25 381-354-355 (includes base panels items 1, 2, CGa-3 381-354-356 3, 4, 5, 6, and 7, plus insulation,...
Page 63 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Replacement parts — jacket Jacket assembly Junction box, 2 x 4 Jacket panel, left side, with insulation Jacket panel, right Jacket panel, side, with insula- top front Natural Gas Propane Gas Natural Gas...
Page 64 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Replacement parts — trim Trim assembly Item Description Manufacturer Manufacturer’s Weil-McLain number part number part number Pressure relief valve, ASME, 30 PSIG, ¾" male inlet Conbraco 10-407-10 511-546-920 Watts M330 Pressure relief valve, ASME, 30 PSIG, ¾" female inlet...
Page 65 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Replacement parts — controls Gas control assembly Item Description Manufacturer Manufacturer’s Weil-McLain number part number part number Standing pilot — Natural gas components Gas valve, " x ", CGa-25 through CGa-6 Honeywell...
Page 66: Dimensions And Ratings
GOLD CGa Gas-Fired Water Boiler — Boiler Manual Dimensions Figure 36 Dimensional drawing — ALL DIMENSIONS IN INCHES Boiler Supply Return Gas connection “A” “D” “W” “H” model tapping tapping & manifold size Vent Vent Jacket Damper number (inches NPT)
Page 67 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Ratings Boiler Input 0–2,000 feet 2,000–4,500 feet Boiler Chimney model (Btuh) Heating altitude altitude I=B=R water Seasonal efficiency number capacity ratings content (% A.F .U.E) breeching (Btuh) (Btuh) (gallons) size Input Output...
Page 68 GOLD CGa Gas-Fired Water Boiler — Boiler Manual Handling ceramic ﬁber and ﬁberglass materials REMOVAL OF COMBUSTION CHAMBER REMOVAL OF FIBERGLASS WOOL LINING OR BASE PANELS The combustion chamber lining or INSTALLATION OF FIBERGLASS WOOL, base insulation panels in this prod- COMBUSTION CHAMBER LINING OR uct contain ceramic ﬁber materials.

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